Flame retarder, flame retardant resin composition and method of producing the flame retarder

ABSTRACT

A flame retardant resin composition is disclosed. An acrylonitrile-styrene based polymer, into which sulfonic acid groups and/or sulfonate groups have been introduced by sulfonating processing with a sulfonating agent containing less than 3 wt % of moisture, is contained in a resin to be made flame retardant, so that flame retardant properties will be conferred on the resin flame resistant.

TECHNICAL FIELD

This invention relates to a flame retarder for imparting flame retardantproperties to a resin composition, a flame retardant resin compositioncontaining this flame retarder, and to a method of producing the flameretarder.

The present invention contains subject matter related to Japanese PatentApplications JP 2004-085477, JP 2004-085479 and JP 2004-085480, allfiled on Mar. 23, 2004, the entire contents of which being incorporatedherein by reference.

BACKGROUND ART

The flame retarders for resin, used in these years for conferring flameretardant properties on a resin composition, may be exemplified by metalhydroxide based (e.g. magnesium hydroxide or aluminum hydroxide) flameretarders, silicon based (e.g. silicone or silica) flame retarders,halogen-based (bromine) flame retarders and phosphorus-based (e.g.phosphate or red phosphorus) flame retarders.

The metal hydroxide based flame retarders suffer from the defect thatthey are added in larger quantities in the resin and hence themechanical properties of the resin are impaired. The silicon-based flameretarders suffer from the defect that the sorts of the resincompositions, the silicon-based flame retarders may be applied to, arelimited. On the other hand, the consumption of halogen-based flameretarders tends to be decreased because they are detected in animals orin woman's milk, or there is fear of generation of bromine-based dioxinon combustion.

Thus, the phosphorus-based flame retarders are currently attractingattention as a substitute material for the above flame retarders.However, the phosphorus-based flame retarders suffer from a problem thatgases may be evolved on injection molding a resin composition, or theresin composition may be lowered in thermal resistance.

In connection with use of the polycarbonate resin, as a resincomposition, a flame retarder for resin of a polystyrene sulfonate resintype, which is a metal salt flame retarder, has been proposed in JPLaid-Open Patent Publications 2001-181342, 2001-181444 and 2001-2941.

The flame retarders for resins, proposed in these Patent publications,suffer from the problem that the resin compositions, the flame retardersmay be applied to, are limited to polycarbonate resins, that the flameretardant effect is insufficient, and that the flame retarders are notdispersed substantially uniformly, that is, that the flame retarders arepoor in compatibility. For this reason, there is raised a demand for aflame retarder for resin exhibiting higher flame retardant properties.

In particular, a flame retarder for resin, proposed in JP Laid-OpenPatent Publication 2002-2941, contains an amide group or a carboxylgroup, liable to take up the moisture, such that, when the resincomposition, containing the flame retarder, is stored for prolongedtime, there is raised such a problem that the resin composition isdiscolored and impaired in appearance, or the resin itself becomesembrittled, that is, the resin is lowered in mechanical strength.

DISCLOSED OF THE INVENTION Problem to be Solved by the Invention

It is an object of the present invention to provide a flame retarderhaving high compatibility with respect to a resin composition and whichis capable of suppressing deterioration in appearance or in mechanicalstrength on prolonged storage of the resin composition. It is also anobject of the present invention to provide a flame retardant resincomposition and a method for producing the flame retarder.

For solving the above problem, the present inventors have conductedperseverant researches, and have found that a styrene-based polymer,containing a preset amount of acrylonitrile as a monomer unit, and intowhich have been introduced preset amounts of sulfonic acid groups and/orsulfonate groups, is superior as a flame retarder for resin. Thisfinding has led to fulfillment of the present invention.

A flame retarder according to the present invention is to be containedin a resin composition to confer flame retardant properties on the resincomposition. The flame retarder comprises an acrylonitrile-styrene basedpolymer containing at least acrylonitrile and styrene. Theacrylonitrile-styrene based polymer has been sulfonated with asulfonating agent containing less than 3 wt % of moisture, so thatsulfonic acid groups and/or sulfonate groups have been introduced intothe acrylonitrile-styrene based polymer.

A flame retardant resin composition according to the present inventioncontains a flame retarder to confer flame retardant properties on theresin composition. The flame retarder includes an acrylonitrile-styrenebased polymer containing at least acrylonitrile and styrene. Theacrylonitrile-styrene based polymer has been sulfonated with asulfonating agent containing less than 3 wt % of moisture, so thatsulfonic acid groups and/or sulfonate groups have been introduced intothe acrylonitrile-styrene based polymer.

A method for producing a flame retarder according to the presentinvention produces a flame retarder to be contained in a resincomposition to confer flame retardant properties on said resincomposition. The method comprises sulfonating the acrylonitrile-styrenebased polymer, containing at least acrylonitrile and styrene, with asulfonating agent containing less than 3 wt % of moisture, forintroducing sulfonic acid groups and/or sulfonate groups into theacrylonitrile-styrene based polymer, to produce a flame retarder.

A method for producing a flame retarder according to the presentinvention produces a flame retarder to be contained in a resincomposition to confer flame retardant properties on said resincomposition. The method comprises reacting a powderedacrylonitrile-styrene based polymer, containing at least acrylonitrileand styrene, with an SO₃ gas for performing sulfonating processing forintroducing sulfonic acid groups and/or sulfonate groups into theacrylonitrile-styrene based polymer.

According to the present invention, since the acrylonitrile-styrenebased polymer, into which sulfonic acid groups and/or sulfonate groupshave been introduced by sulfonating processing with a sulfonating agentcontaining less than 3 wt % of the moisture, is used as a flameretarder, the sorts of the resin composition, that can properly be madeflame retardant, can be proliferated, while the flame retarder may bedispersed substantially evenly in the resin composition.

Moreover, according to the present invention, since anacrylonitrile-styrene based polymer, containing sulfonic acid groupsand/or sulfonate groups introduced therein, is contained as a flameretarder in a resin composition, a frame retardant resin composition ofsuperior quality may be obtained in which defects in appearance or poormechanical strength are not produced on prolonged storage.

A flame retarder according to the present invention is to be containedin a resin composition to confer flame retardant properties on the resincomposition. With the flame retarder, sulfonic acid groups and/orsulfonate groups have been introduced into an aromatic polymercontaining monomer units having aromatic skeletons in an amount rangingbetween 1 mol % and 100 mol %, with the polymer having a weight averagemolecular weight ranging between 25000 and 10000000. The sulfur contentin the sulfonic acid groups and/or sulfonate groups ranges between 0.001wt % and 20 wt %.

A flame retardant resin composition according to the present inventioncontains a flame retarder which confers flame retardant properties onthe resin composition. With the flame retarder, sulfonic acid groupsand/or sulfonate groups have been introduced into an aromatic polymercontaining monomer units having aromatic skeletons in an amount rangingbetween 1 mol % and 100 mol %, with the polymer having a weight averagemolecular weight ranging between 25000 and 10000000. The sulfur contentof the sulfonic acid groups and/or sulfonate groups ranges between 0.001wt % and 20 wt %.

According to the present invention, since an aromatic polymer of apreset molecular weight, into which have been introduced preset amountsof sulfonic acid groups and/or sulfonate groups, is used as a flameretarder, the sorts of the resin composition, that can properly be madeflame retardant, can be proliferated, while the flame retarder may bedispersed substantially evenly in the resin composition.

Moreover, according to the present invention, since anacrylonitrile-styrene based polymer, containing sulfonic acid groupsand/or sulfonate groups introduced therein, is contained as a flameretarder in the resin composition, a frame retardant resin compositionof superior quality may be obtained in which defects in appearance orpoor mechanical strength are not produced on prolonged storage.

A flame retarder according to the present invention is to be containedin a resin composition to confer flame retardant properties on the resincomposition. The flame retarder includes an aromatic polymer containingmonomer units having aromatic skeletons ranging between 1 mol % and 100mol %. Into the aromatic polymer, sulfonic acid groups and/or sulfonategroups have been introduced in an amount ranging between 0.01 mol % and14.9 mol %.

A flame retardant resin composition according to the present inventioncontains a flame retarder to confer flame retardant properties on theresin composition. The flame retarder includes an aromatic polymercontaining monomer units having aromatic skeletons ranging between 1 mol% and 100 mol %. Into the aromatic polymer, sulfonic acid groups and/orsulfonate groups have been introduced in an amount ranging between 0.01mol % and 14.9 mol %.

According to the present invention, since the aromatic polymer, intowhich have been introduced preset amounts of sulfonic acid groups and/orsulfonate groups, is used as a flame retarder, the sorts of the resincomposition, that can properly be made flame retardant, can beproliferated, while the flame retarder may be dispersed substantiallyevenly in the resin composition.

Moreover, according to the present invention, since an aromatic polymer,into which sulfonic acid groups and/or sulfonate groups have beenintroduced by sulfonating processing with a sulfonating agent containingless than 3 wt % of moisture, is contained in the resin composition, asa flame retarder, a flame retardant resin composition of superiorquality may be obtained in which defects in appearance or poormechanical strength are not produced on prolonged storage.

Other objects and advantages of the present invention will become moreapparent from the embodiments and examples which will now be explained.

BEST MODE FOR CARRYING OUT THE INVENTION

A flame retarder, a flame retardant resin composition and a method forproducing the flame retarder, according to the present invention, willnow be described in detail.

The flame retardant resin composition, embodying the present invention,is a resin material used for household electrical products or fibers. Itis a resin material, which is to be made flame retardant, and which hasbeen made flame retardant by the flame retarder contained therein.

The flame retarder, contained in the flame retardant resin composition,is a polymer containing at least acrylonitrile and styrene, and intowhich a preset amount(s) of sulfonic acid group and/or a sulfonate grouphave been introduced.

Specifically, the polymer containing acrylonitrile and styrene, referredto below as an acrylonitrile-styrene based polymer, may be enumeratedby, for example, an acrylonitrile-styrene copolymer (AS), anacrylonitrile-butadiene-styrene copolymer (ABS), anacrylonitrile-chlorinated polyethylene-styrene resin (ACS), anacrylonitrile-styrene-acrylate copolymer (ASA), anacrylonitrile-ethylene propylene rubber-styrene copolymer (AES), and anacrylonitrile-ethylene-propylene-diene-styrene resin (AEPDMS). These maybe used either alone or in combination.

In the acrylonitrile-styrene based polymer, the acrylonitrile unitscontained therein are preferably in the range from 1 mol % to 90 mol %,more preferably in the range from 10 mol % to 80 mol % and mostpreferably in the range from 20 mol % to 70 mol %.

If the amount of the acrylonitrile units, contained in theacrylonitrile-styrene based polymer, is less than 1 mol %, the flameretarder becomes difficult to disperse substantially evenly in the flameretardant resin composition. That is, the flame retarder becomes poor incompatibility with respect to the resin composition, such that itbecomes difficult to achieve high flame retardant properties. If, on theother hand, the amount of the acrylonitrile units, contained in theacrylonitrile-styrene based polymer, is more than 90 mol %, theintroducing rate of sulfonic acid groups or sulfonate groups into theacrylonitrile-styrene based polymer becomes lower with the consequencethat only limited effects of donating flame retardant properties to theflame retardant resin composition may be achieved.

On the other hand, the amount of styrene units, contained in theacrylonitrile-styrene based polymer, is preferably in the range from 1to 99 mol %, more preferably in the range from 10 to 90 mol % and mostpreferably in the range from 20 to 80 mol %.

If the amount of styrene units, contained in the acrylonitrile-styrenebased polymer, is less than 1 mol %, the introducing rate of thesulfonic acid groups or sulfonate groups becomes lower, such thatoptimum flame retardant properties cannot be achieved. If, on the otherhand, the amount of styrene units, contained in theacrylonitrile-styrene based polymer, is more than 99 mol %, the flameretarder becomes poor in compatibility with respect to the resincomposition, such that it becomes difficult to achieve superior flameretardant properties.

Meanwhile, the acrylonitrile units and the styrene units may bealternately copolymerized, or may be block polymerized. Preferably, theacrylonitrile units and the styrene units are alternately copolymerizedfor conferring adequate flame retardant properties on the flameretardant resin composition.

It is noted that the weight average molecular weight of theacrylonitrile-styrene based polymer is preferably 1000 to 10000000, morepreferably 5000 to 1000000 and most preferably 20000 to 500000.

If the weight average molecular weight of the acrylonitrile-styrenebased polymer deviates from the range from 5000 to 10000000, the flameretarder becomes difficult to disperse substantially evenly in the resinwhich is to be flame retardant, that is, the flame retarder becomes poorin compatibility with respect to the resin, with the result that itbecomes difficult to confer suitable flame retardant properties to theflame retardant resin composition.

In the acrylonitrile-styrene based polymer, the styrene unit holds abenzene ring, and hence is useful in introducing sulfonic acid groupsand/or sulfonate groups as later explained. On the other hand, theacrylonitrile unit contributes to improving the compatibility of thepolymer with respect to the resin composition.

As the acrylonitrile-styrene based polymer, used-up redeemed materialsor scraps from the plant may be used. That is, the acrylonitrile-styrenebased polymer, which serve as a feedstock material, is superior inrecycling performance and contributes to cost reduction.

The method for introducing the sulfonic acid groups and/or sulfonategroups into the acrylonitrile-styrene based polymer may be exemplifiedby a method of sulfonating the acrylonitrile-styrene based polymer witha preset sulfonating agent.

The sulfonating agent, used for sulfonating an acrylonitrile-styrenebased polymer, preferably contains less than 3 wt % of the moisture.Specifically, the sulfonating agent is one or more selected from thegroup consisting of sulfuric anhydride, fuming sulfuric acid,chlorosulfonic acid and polyalkylbenzene sulfonic acid. A complex of,for example, alkyl phosphates or dioxane with Lewis bases may also beused as the sulfonating agent.

If, with the use of, for example, concentrated sulfuric acid, with thewater content of 96 wt %, as a sulfonating agent, theacrylonitrile-styrene based polymer is sulfonated to produce a flameretarder, the cyano groups in the polymer are hydrolyzed and therebyconverted into amide groups or carboxyl groups, exhibiting highhygroscopicity, such that a flame retarder containing these amide orcarboxyl groups is generated. If the flame retarder, containing largerquantities of the amide groups or carboxyl groups, is used, excellentflame retardant properties can be conferred on the flame retardant resincomposition. However, there is fear that water is taken up from outsidewith lapse of time so that inconveniences such as change in color of theflame retardant resin composition and consequent impairment inappearance or deterioration in the mechanical strength of the resin mayarise. Specified examples of this type of the flame retarder arepolystyrene sulfonate flame retarder as proposed in, for example, the JPLaid-Open Patent Publication 2001-2941.

In light of the above, the method of sulfonating theacrylonitrile-styrene based polymer may be exemplified by a methodconsisting in adding a preset amount of the sulfonating agent to asolution, obtained on dissolving the acrylonitrile-styrene based polymerin an organic solvent (chlorine-based solvent), to carry out thereaction. There is also such a method consisting in adding a presetamount of a preset sulfonating agent to a liquid obtained on dispersinga pulverulent acrylonitrile-styrene based polymer in an organic solvent(the liquid which is not a solution) to carry out the reaction. Thereare also such a method consisting in directly injecting anacrylonitrile-styrene based polymer into a sulfonating agent, and such amethod consisting in directly spraying a sulfonating gas, specifically agas of a sulfuric anhydride (SO₃), to a pulverulentacrylonitrile-styrene based polymer, to carry out the reaction.

To the acrylonitrile-styrene based polymer are introduced the sulfonicacid groups (—SO₃H) or the sulfonate groups either directly or as thesegroups have been neutralized with ammonia or amine compounds.Specifically, the sulfonates may be enumerated by, for example, Nasalts, K salts, Li salts, Ca salts, Mg salts, Al salts, Zn salts, Sbsalts and Sn salts of sulfonic acid.

It is noted that higher flame retardant properties may be conferred onthe resin composition when sulfonate groups, rather than the sulfonicacid groups, have been introduced into the acrylonitrile-styrene basedpolymer of the flame retarder.

Also, in the flamer retarder, the amount of the sulfonic acid groupsand/or sulfonate groups, introduced into the acrylonitrile-styrene basedpolymer of the flame retarder, is based on the content of sulfur (S) inthe flame retarder. Specifically, the sulfur content in the flameretarder is preferably 0.001 to 16 wt %, more preferably 0.01 to 10 wt %and most preferably 0.1 to 5 wt %.

If the sulfur content in the flame retarder is less than 0.001 wt %, theamount of the sulfonic acid groups and/or the sulfonate groups,introduced into the acrylonitrile-styrene based polymer, is so smallthat it becomes difficult to confer flame retardant properties on theflame retardant resin composition. If conversely the sulfur content inthe flame retarder is more than 16 wt %, the amount of sulfonic acidgroups and/or the sulfonate groups introduced into theacrylonitrile-styrene based polymer becomes excessive, so that there isfear that the flame retarder is lowered in compatibility with respect tothe resin composition. There is also fear that the flame retardant resincomposition is deteriorated in mechanical strength with lapse of time,or the blooming time becomes longer at the time of combustion.

The resin composition, in which the aforementioned flame retarder is tobe contained and which is to be thereby made flame retardant, may beenumerated by, for example, polycarbonate (PC), anacrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), anacrylonitrile-styrene copolymer (AS), polyvinyl chloride (PVC),polyphenylene oxide (PPO), polyethylene terephthalate (PET),polybutylene terephthalate (PBT), polysulfone (PSF), thermoplasticelastomer (TPE), polybutadiene (PB), polyisoprene (PI), nitrile rubber(acrylonitrile-butadiene rubber, nylon, and polylactic acid (PLA). Suchresin composition containing one or more of the above resins in anamount of 5 wt % or more is used. That is, one of the above resins or amixture containing two or more of the above resins (alloy) may be usedas the resin to be made flame retardant.

The resin composition, in which the aforementioned flame retarder is tobe contained and which is to be thereby made flame retardantparticularly effectively, may be enumerated by, for example, ABS,(HI)PS, AS, PPO, PBT, PET, PVC, PLA, an ABS/PC alloy, a PS/PC alloy, anAS/PC alloy, an HIPS/PC alloy, a PET/PC alloy, a PBT/PC alloy, a PVC/PCalloy, a PLA (polylactic acid)/PC alloy, a PPO/PC alloy, a PS/PPO alloy,a HIPS/PPO alloy, an ABS/PET alloy and a PET/PBT alloy. These resincompositions may be used either alone or in combination.

Similarly to the aforementioned flame retarder, the resin to be madeflame retardant may be used-up redeemed materials or scraps from theplant. That is, in the flame retardant resin composition, the resin tobe made flame retardant, which serves as a feedstock material, issuperior in recycling performance, and contributes to cost reduction.

In the above-described flame retardant resin composition, theacrylonitrile-styrene based polymer, which has been sulfonated with asulfonating agent containing less than 3 wt % of moisture, and intowhich the sulfonic acid groups and/or the sulfonate groups have therebybeen introduced, is used as a flame retarder. This may increase thenumber of sorts of the resins which are to be optimally made flameretardant.

Moreover, in this flame retardant resin composition, superior flameretardant properties may be developed because the acrylonitrile units ofthe acrylonitrile-styrene based polymer, acting as a flame retarder,operate for substantially evenly dispersing the flame retarder in theresin which is to be rendered flame retardant.

In addition, in this flame retardant resin composition, the flameretarder contained therein has been produced by sulfonating processingwith a sulfonating agent, containing less than 3 wt % of water, suchthat none of the amide groups or carboxylic groups, exhibiting highhygroscopicity, is introduced into the flame retarder. Hence, it becomespossible to prohibit such inconvenience that water is taken up onprolonged storage so that the resin composition is changed in color,deteriorated in appearance or lowered in mechanical strength.

Furthermore, in the flame retardant resin composition, the content ofthe flame retarder is preferably 0.0001 to 30 wt %, more preferably0.001 to 10 wt % and most preferably 0.01 to 3 wt %.

If the content of the flame retarder is less than 0.0001 wt %, itbecomes difficult to effectively confer flame retardant properties tothe resin composition. If, on the other hand, the content of the flameretarder is more than 30 wt %, the effect becomes negative, that is, theresin composition to be rendered flame retardant tends to becombustible.

That is, the present flame retarder may be added in a minor quantity tothe resin to be rendered flame retardant, in which case the flameretardant properties may be efficaciously conferred on the flameretardant resin composition as an ultimate product.

The above-described flame retardant resin composition may also be addedby known routine flame retarders, in addition to the above-describedflame retarders, for further improving the flame retardant properties.

These known routine flame retarders may be enumerated by, for example,organic phosphate based flame retarders, halogenated phosphate basedflame retarders, inorganic phosphorus based flame retarders, halogenatedbisphenol based flame retarders, halogenated compound based flameretarders, antimony based flame retarders, nitrogen based flameretarders, boron based flame retarders, metal salt based flameretarders, inorganic flame retarders and silicon based flame retarders.These flame retarders may be used either singly or in combination.

Specifically, the organic phosphate or phosphite based flame retardersmay be enumerated by, for example, triphenyl phosphate, methyl neobenzylphosphate, pentaerythrytol diethyl diphosphate, methyl neopentylphosphate, phenyl neopentyl phosphate, pentaerythrytol diphenyldiphosphate, dicyclopentyl hypodiphosphate, dineopentyl hypodiphosphite,phenyl pyrocatechol phosphite, ethyl pyrocatechol phosphate anddipyrocatechol hypodiphosphate. These may be used either alone or incombination.

The halogenated phosphate based flame retarders may be enumerated by,for example, tris(β-chloroethyl)phosphate, tris(dicyclopropyl)phosphate,tris(β-bromoethyl)phosphate, tris(dibromopropyl)phosphate,tris(chloropropyl)phosphate, tris(dibromophenyl)phosphate,tris(tribromophenyl)phosphate, tris(tribromoneopentyl)phosphate,condensed polyphosphate and condensed polyphosphonate. These may be usedeither alone or in combination.

The inorganic phosphorus based flame retarder may be exemplified by, forexample, red phosphorus and inorganic phosphates. These may be usedeither alone or in combination.

The halogenated bisphenol based flame retarder may be enumerated by, forexample, tetrabromobisphenol A, oligomers thereof andbis(bromoethylether)tetrabromobisphenol A. These may be used eitheralone or in combination.

The halogen compound based flame retarder may be enumerated bydecabromodiphenyl ether, hexabromobenzene, hexabromocyclododecane,tetrabromo phthalic anhydride, (tetrabromobiphenol)epoxy oligomer,hexabromobiphenyl ether, tribromophenol, dibromocresyl glycidyl ether,decabromodiphenyl oxide, halogenated polycarbonate, halogenatedpolycarbonate copolymers, halogenated polystyrene, halogenatedpolyolefin, chlorinated paraffin and perchlorocyclodecane. These may beused either alone or in combination.

The antimony based flame retarder may be enumerated by, for example,antimony trioxide, antimony tetroxide, antimony pentoxide and sodiumantimonite. These may be used either alone or in combination.

The nitrogen-based flame retarders may be enumerated by, for example,melamine, alkyl group substituted or aromatic group substitutedmelamine, melamine cyanurate, melamine isocyanurate, melamine phosphate,triazine, guanidine compounds, urea, a variety of cyanuric acidderivatives and phosphasene compounds. These may be used either alone orin combination.

Examples of boric acid based flame retarder may include zinc borate,zinc metaborate and barium metaborate. These may be used either alone orin combination.

Examples of metal salt based flame retarder include alkali metal saltsand alkali earth metal salts of perfluoroalkane sulfonic acid,alkylbenzene sulfonic acid, halogenated alkylbenzene sulfonic acid,alkylsulfonic acid and naphthalene sulfonic acid. These may be usedeither alone or in combination.

The inorganic flame retarder may be enumerated by, for example,magnesium hydroxide, aluminum hydroxide, barium hydroxide, calciumhydroxide, dolomite, hydrotalcite, basic magnesium carbonate,hydrogenated zirconium, hydrates of inorganic metal compounds, such ashydrates of tin oxide, metal oxides, such as aluminum oxide, iron oxide,titanium oxide, manganese oxide, magnesium oxide, zirconium oxide, zincoxide, molybdenum oxide, cobalt oxide, bismuth oxide, chromium oxide,tin oxide, nickel oxide, copper oxide and tungsten oxide, powders ofmetals, such as aluminum, iron, copper, nickel, titanium, manganese,tin, zinc, molybdenum, cobalt, bismuth, chromium, tungsten and antimony,and carbonates, such as zinc carbonate, magnesium carbonate, calciumcarbonate and barium carbonate. These may be used either alone or incombination.

Out of the inorganic flame retarders, magnesium hydroxide, aluminumhydroxide, talc, which is a hydrated silicate of magnesium, basicmagnesium carbonate, mica, hydrotalcite and aluminum are desirable fromthe perspective of flame retardant properties and from economicconsiderations. Meanwhile, used-up redeemed materials or scraps from theplant may be used as inorganic flame retarders.

Examples of silicon-based flame retarders include polyorganosiloxaneresins (silicone or organic silicates) and silica. These may be usedeither alone or as a mixture. The polyorganosiloxane resins may beexemplified by polymethylethyl silixane resins, polydimethyl silixaneresins, polymethyl phenyl siloxane resins, polydiphenyl siloxane resins,polydiethyl siloxane resins, polyethylphenyl siloxane resins, andmixtures thereof.

In the alkyl moiety portions of each of these polyorganosiloxane resins,there may be contained functional groups, such as alkyl groups, alkoxygroups, hydroxyl groups, amino groups, carboxyl groups, silanol groups,mercapto groups, epoxy groups, vinyl groups, aryloxy groups, polyoxyalkylene groups, hydrogen groups or halogens. In particular, there maypreferably be contained alkyl groups, alkoxy groups, hydroxyl groups andvinyl groups.

The polyorganosiloxane resins are of the average molecular weight notless than 100 and preferably in a range from 500 to 5000000, and may bein the form of oil, varnish, gum, powders or pellets. As for silica, itis preferably surface-processed with a silane coupling agent ofhydrocarbon based compounds.

The above-described known flame retarders are usually contained in anamount of 0.001 to 50 wt %, preferably in an amount of 0.01 to 30 wt %and more preferably in an amount of 0.1 to 10 wt %, based on the weightof the resin to be rendered flame retardant, depending on the sort ofthe flame retarder, the level of flame retardant performance needed, andon the sort of the resin to be rendered flame retardant.

The flame retardant resin composition, containing the aforementionedflame retarder, may also be added by, for example, known routineinorganic fillers, for improving mechanical strength or for furtherimproving flame retardant properties.

These known routine inorganic fillers may be enumerated by, for example,crystalline silica, fused silica, alumina, magnesia, talc, mica, kaolin,clay, diatomaceous earth, calcium silicate, titanium oxide, glassfibers, calcium fluoride, calcium phosphate, barium phosphate, calciumphosphate, carbon fibers, carbon nano-tubes and potassium titanatefibers. Of these, one or more in the form of a mixture may be used. Fromamong these inorganic fillers, talc, mica, carbon, glass or carbonnano-tubes may preferably be employed.

The inorganic fillers are contained in an amount ranging from 0.1 to 90wt %, preferably in an amount ranging from 0.5 to 50 wt % and morepreferably in an amount ranging from 1 to 30 wt %, based on the weightof the flame retardant resin composition.

If the content of the inorganic filler is less than 0.1 wt %, the flameretardant resin composition is lower in rigidity or deteriorated in itseffect of improving the flame retardant properties. If, on the otherhand, the content of the inorganic filler is higher than 90 wt %, theremay be presented such deficiencies that the fused flame retardant resincomposition becomes lower in fluidity or is deteriorated in mechanicalstrength at the time of injection molding of the flame retardant resincomposition.

Moreover, the flame retardant resin composition may be added by, forexample, fluoro olefin resins, besides the aforementioned flameretardant, for the purpose of suppressing the dripping phenomenon at thetime of combustion.

The fluoro olefin resins, capable of suppressing the drippingphenomenon, may be exemplified by difluoroethylene polymers,tetrafluoroethylen polymers, tetrafluoroethylen-hexafluoropropylenecopolymers and copolymers of tetrafluoroethylen and ethylenic monomers.These may be used either alone or in combination.

Of these fluoro olefin resins, tetrafluoroethylene polymers are mostpreferred. The average molecular weight of the tetrafluoroethylenepolymers is 50000 or more and preferably in a range from 100000 to20000000. Meanwhile, the fluoro olefin resins exhibiting fibril-formingproperties are most preferred.

The content of the fluoro olefin resins is in a range from 0.001 to 5 wt%, preferably 0.005 to 2 wt % and more preferably 0.01 to 0.5 wt %,based on the weight of the flame retardant resin composition.

If the content of the fluoro olefin resins becomes less than 0.001 wt %,it becomes difficult to suppress the dripping phenomenon. If converselythe content of the fluoro olefin resins becomes larger than 5 wt %, theeffect in suppressing the dripping phenomenon is saturated, thuspresenting inconveniences such as high cost or poor mechanical strength.

Moreover, the flame retardant resin composition may be added by, forexample, an anti-oxidant (phenol-based, phosphorus-based or sulfur-basedanti-oxidant), an anti-static agent, a UV absorber, a light stabilizer,a plasticizer, a compatibility promoting agent, a coloring agent(pigments or dyestuffs), a bactericidal agent, an anti-hydrolysis agentor a surface processing agent, in addition to the aforementioned flameretarder, for the purpose of improving injection moldability,shock-proofness, appearance, thermal resistance, weatherability andrigidity.

In producing the above-described flame retardant resin composition, theflame retarder, resin to be made flame retardant, and the otheradditives, are dispersed substantially evenly in a kneading unit, suchas a tumbler, a reblender, a mixer, an extruder or a co-kneader, and theresulting mass is molded to a preset shape by any suitable moldingmethod, such as injection molding, injection compression molding,extrusion molding, blow molding, vacuum molding, press molding, foammolding or supercritical molding.

The molded product, formed of the flame retardant resin composition, isused in many fields, as an enclosure or a component part for e.g.domestic electrical utensil, cars, information equipment, businessequipment, telephone sets, stationeries, furniture or fiber, which hasbeen made flame retardant.

Several preferred Examples for testifying to the merit of the presentinvention and several Comparative Examples for comparison to thepreferred Examples will now be described.

First, several inventive samples and control samples of a flameretarder, to be contained in the preferred Examples and the ComparativeExamples, were prepared.

(Inventive Sample 1)

In preparing the inventive sample 1, 3 g of anacrylonitrile-butadiene-styrene copolymer resin, as anacrylonitrile-styrene based polymer, made up by 39 mol % ofacrylonitrile units, 50 mol % of styrene units and 11 mol % of butadieneunits, and which was pulverized to a particle size not larger than 32mesh, were introduced into a round-bottom flask, which was previouslycharged with 24 g of cyclohexane. The pulverulent resin, thus charged,was dispersed therein, to prepare a slurried polymer solution. Then, 7 gof sulfuric anhydride were added to the polymer solution and agitatedfor one hour at ambient temperature by way of sulfonating theacrylonitrile-styrene based polymer. Then, residual gases in the flaskwere removed by air bubbling, and solid contents were taken out by aglass filter. The solid contents, thus obtained, were injected intowater. After adjusting the pH to 7 with potassium hydroxide, theresulting sold contents were again filtered, using a glass filter, anddried in a vacuum drier (50° C.×10 hours) to yield a brown flameretarder. In this manner, an acrylonitrile-styrene based polymer, havingsulfonic acid groups introduced therein, could be prepared as a flameretarder.

The flame retarder, thus prepared, was subjected to elementary analysis,using a combustion flask method. The sulfur content in the flameretarder prepared was 14 wt %. The flame retarder was also analyzed asto its ingredients, using a Fourier transform-infrared spectrophotometer(FT-IR). The result of the analysis indicated no characteristicabsorption proper to amide or carboxyl groups.

(Inventive Sample 2)

In preparing an inventive sample 2, a transparent reel material of aused-up cassette for business use, as an acrylonitrile-styrene basedpolymer, was crushed and pulverized into powders of theacrylonitrile-styrene based copolymer resin (acrylonitrile units: 44 mol%; styrene units: 56 mol %) capable of passing through a 83 mesh screen.2 g of the powdered material were charged into a round-bottom flask andstirred. As the powdered material was kept in an agitated state, an SO₃gas, emanated from 3 g of fuming sulfuric acid, was blown at ambienttemperature into the flask over four hours, by way of sulfonating theacrylonitrile-styrene based polymer. Air was then blown into theround-bottom flask to remove the residual SO₃ gas from the insidethereof. Water was then added into the flask and the pH value of thewater was adjusted to 7 with sodium hydroxide. The solid content(reformed resin) was taken out by filtering through a glass filter anddried (vacuum driver: 50° C.×10 hours) to yield a flame retarder in theform of white powders). That is, the inventive sample 2 is again anacrylonitrile-styrene based polymer into which were introduced sulfonicacid groups.

The sulfur content in the flame retarder, thus obtained, was measured inthe same way as in the aforementioned inventive sample 1. The sulfurcontent was found to be 2.1 wt %. The elementary analysis of the flameretarder was carried out in the same way as in the inventive sample 1.No characteristic absorption proper to the amide or carboxyl groups wasnoticed.

(Inventive Sample 3)

In the inventive sample 2, flame retarder in the form of white powderscould be prepared in the same way as in the above-described inventivesample 2, except setting the sulfonating time duration to ten minutes.The sulfur content in the flame retarder, thus obtained, was measured inthe same way as in the aforementioned inventive sample 1. The sulfurcontent was found to be 0.05 wt %. The elementary analysis of the flameretarder was carried out in the same way as in the inventive sample 1.No characteristic absorption proper to the amide or carboxyl groups wasnoticed. Hence, the inventive sample 3 is again an acrylonitrile-styrenebased polymer into which were introduced sulfonic acid groups.

(Control Sample 1)

In the control sample 1, a flame retarder was prepared in the same wayas in the aforementioned inventive sample 2, except using a polystyreneresin (molecular weight: 20000) in place of the acrylonitrile-styrenebased polymer. That is, the control sample 1 differs from the inventivesamples in that a sulfonic acid group has been introduced into thepolystyrene resin.

The sulfur content in the flame retarder, thus obtained, was measured inthe same way as in the aforementioned inventive sample 1. The sulfurcontent was found to be 2.2 wt %. The elementary analysis of the flameretarder was carried out in the same way as in the inventive sample 1.No characteristic absorption proper to the amide or carboxyl groups wasnoticed.

(Control Sample 2)

In the control sample 2, sodium polystyrene sulfonate (weight averagemolecular weight: 18000) was used as a flame retarder. The sulfurcontent in the flame retarder, thus obtained, was measured in the sameway as in the aforementioned inventive sample 1. The sulfur content wasfound to be 14 wt %. The elementary analysis of the flame retarder wasthen carried out in the same way as in the inventive sample 1. Nocharacteristic absorption proper to the amide or carboxyl groups wasnoticed.

(Control Sample 3)

In preparing the control sample 3, 96 wt % of concentrated sulfuricacid, as a sulfonating agent used for sulfonation processing, was heatedto 80° C. In this sulfonating agent, the same resin powders as thoseused in the inventive sample 2 were charged and reacted for one hour.After the end of the reaction, the solid content was recovered onfiltering. In the second washing with water, the pH value was adjustedto 7 with sodium hydroxide. The solid content, obtained on filtering,was dried to give a flame retarder. The sulfur content in the flameretarder, thus obtained, was measured in the same way as in theaforementioned inventive sample 1. The sulfur content was found to be 8wt %. The elementary analysis of the flame retarder was carried out inthe same way as in the inventive sample 2. The analysis indicatedabsorption characteristic of the amide groups or carboxyl groups. Thatis, the control sample 3 is an acrylonitrile-styrene polymer containingamide groups and carboxylic groups introduced in addition to thesulfonic acid groups.

The flame retarders of the inventive samples and the control samples,obtained as described above, were introduced into a preset resin, whichis to be made flame retardant, by way of preparing Examples andComparative Examples.

EXAMPLE 1

In an Example 1, 99.8 parts by weight of a polycarbonate resin(bisphenol A), referred to below as PC, as a resin which is to be madeflame retardant, 0.1 part by weight of the inventive sample 2, as aflame retarder, and 0.1 part by weight of polytetrafluoroethyleneexhibiting fibril-forming properties, referred to below as PTFE, as ananti-drip agent, were mixed together to prepare a flame retardant resinprecursor. This flame retardant resin precursor was supplied to aninjection molding machine, kneaded at a preset temperature andpelletized. The pellets, thus prepared, were charged into an extruder tocarry out injection molding at a preset temperature. In this manner, astrip-shaped test piece, 1.5 mm in thickness, formed of a flameretardant resin composition, was prepared.

EXAMPLE 2

In the Example 2, a strip-shaped test piece was prepared in the same wayas in the above-described Example 1, except mixing 84.3 parts by weightof PC and 15 parts by weight of an acrylonitrile-butadiene-styrenecopolymer resin (acrylonitrile/butadiene/styrene weight ratio=24/20/56),referred to below as ABS resin, as resins to be made flame retardant,0.1 part by weight of the inventive sample 1, as a flame retarder, 0.5part by weight of polymethyl phenyl siloxane, referred to below as SI,as a silicon based flame retarder, by way of another flame retarder, and0.1 part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

EXAMPLE 3

In the Example 3, a strip-shaped test piece was prepared in the same wayas in the above-described Example 1, except mixing 89.2 parts by weightof PC and 10 parts by weight of rubber-modified polystyrene(polybutadiene/polystyrene weight ratio=10/90), referred to below as aHIPS resin, 0.5 part by weight of the inventive sample 3, as a flameretarder, and 0.3 part by weight of PTFE, as an anti-drip agent, toprepare a flame retardant resin precursor.

EXAMPLE 4

In the Example 4, a strip-shaped test piece was prepared in the same wayas in the above-described Example 1, except mixing 89.5 parts by weightof PC and 10 parts by weight of an acrylonitrile-styrene copolymer resin(weight ratio acrylonitrile/styrene=25/75), referred to below as ASresin, as resins to be made flame retardant, 0.2 part by weight of theinventive sample 1, as a flame retarder, 0.1 part by weight of SI, asanother flame retarder, and 0.2 part by weight of PTFE as an anti-dripagent, to prepare a flame retardant resin precursor.

EXAMPLE 5

In the Example 5, a strip-shaped test piece was prepared in the same wayas in the above-described Example 1, except mixing 84 parts by weight ofPC and 15 parts by weight of polyethylene terephthalate, referred tobelow as PET, as resins to be made flame retardant, 0.2 part by weightof the inventive sample 2, as a flame retarder, 0.5 part by weight ofSI, as another flame retarder, and 0.3 part by weight of PTFE as ananti-drip agent, to prepare a flame retardant resin precursor.

EXAMPLE 6

In the Example 6, a strip-shaped test piece was prepared in the same wayas in the above-described Example 1, except mixing 48.8 parts by weightof PC and 50 parts by weight of polylactic acid, referred to below asPLA, as resins to be made flame retardant, 0.5 part by weight of theinventive sample 2, as a flame retarder, 0.5 part by weight of SI, asanother flame retarder, and 0.2 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 1

In the Comparative Example 1, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 99.8parts by weight of PC, as a resin to be made flame retardant, 0.1 partby weight of the control sample 1, as a flame retardant, and 0.1 part byweight of PTFE, as an anti-drip agent, to prepare a flame retardantresin precursor.

COMPARATIVE EXAMPLE 2

In the Comparative Example 2, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 99.8parts by weight of PC, as a resin to be made flame retardant, 0.1 partby weight of the control sample 2, as a flame retarder, and 0.1 part byweight of PTFE, as an anti-drip agent, to prepare a flame retardantresin precursor.

COMPARATIVE EXAMPLE 3

In the Comparative Example 3, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 99.8parts by weight of PC, as a resin to be made flame retardant, 0.1 partby weight of the control sample 3, as a flame retarder, and 0.1 part byweight of PTFE, as an anti-drip agent, to prepare a flame retardantresin precursor.

COMPARATIVE EXAMPLE 4

In the Comparative Example 4, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 84.3parts by weight of PC and 15 parts by weight of an ABS resin, as resinsto be made flame retardant, 0.1 part by weight of the control sample 2,as a flame retarder, 0.5 part by weight of SI, as another flameretarder, and 0.1 part by weight of PTFE, as an anti-drip agent, toprepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 5

In the Comparative Example 5, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 89.2parts by weight of PC and 10 parts by weight of the HIPS resin, asresins to be made flame retardant, 0.5 part by weight of the controlsample 1, as a flame retarder, and 0.3 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 6

In the Comparative Example 6, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 89.5parts by weight of PC and 10 parts by weight of an AS resin, as resinsto be made flame retardant, 0.2 part by weight of the control sample 3,as a flame retarder, 0.1 part by weight of SI, as another flameretarder, and 0.2 part by weight of PTFE, as an anti-drip agent, toprepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 7

In the Comparative Example 7, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 84 partsby weight of PC and 15 parts by weight of PET, as resins to be madeflame retardant, 0.2 part by weight of the control sample 2, as a flameretarder, 0.5 part by weight of SI, as another flame retarder, and 0.3part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

COMPARATIVE EXAMPLE 8

In the Comparative Example 8, a strip-shaped test piece was prepared inthe same way as in the above-described Example 1, except mixing 48.8parts by weight of PC and 50 parts by weight of PLA, as resins to bemade flame retardant, 0.5 part by weight of the control sample 1, as aflame retardant, 0.5 part by weight of SI, as another flame retarder,and 0.2 part by weight of PTFE, as an anti-drip agent, to prepare aflame retardant resin precursor.

The test on combustibility and the test on appearance were then carriedout on the respective Examples and Comparative Examples.

The tests on combustibility were conducted as perpendicularcombustibility tests in accordance with V-0, V-1 and V-2 prescriptionsof UL 94 (Underwriters' Laboratory Subject 94). Specifically, five testpieces each of the Examples and the Comparative Examples were provided,and a burner flame was applied to each of the strip-shaped test piecessupported substantially upright. This state was maintained for tenseconds and thereafter the burner flame was separated from the testpieces. When the flame was extinguished, the burner flame was appliedfor further ten seconds, after which the burner flame was separated fromthe test pieces. Decision was given at this time on the basis of the sumof the time duration of combustion with flame after the end of the firstflame contact with the test pieces, the time duration of combustion withflame after the end of the second flame contact with the test pieces,the time duration of combustion with flame after the end of the secondflame contact with the test pieces, and the time duration of combustionwithout flame after the end of the second flame contact with the testpieces, the sum of time durations of combustion with flame of the fivetest pieces, and the presence/absence of the droppings of combustion.The V-0 prescription provides that combustion with flame shall come to aclose within ten seconds for the first and second combustion events. TheV-1 and V-2 prescriptions provide that combustion with flame shall cometo a close within 30 seconds for the first and second combustion events.The sum of the time duration of the second combustion with flame and thetime duration of the second combustion without flame is less than 30seconds for the V-0 prescription, while the same sum for the V-1 and V-2prescriptions is less than 60 seconds. The sum of the time durations ofcombustion with flame of the five test pieces is less than 50 secondsfor the V-0 prescription, while the same sum for the V-1 and V-2prescriptions is less than 250 seconds. The droppings of combustion aretolerated only for the V-2 prescription. That is, with the UL combustiontest method (UL 94), the flame retardant properties become higher in theorder of the V-0, V-1 and V-2.

Turning to the test on the appearance, the test pieces of the Examplesand the Comparative Examples were exposed for 30 days in a constanttemperature constant pressure vessel of 80° C. atmosphere and 80%relative humidity, and the appearance of the test pieces was checkedvisually. The case without changes in color was indicated with ∘ and thecase with changes in color was indicated with x.

The results of evaluation of the combustibility test and the appearancetest of the Examples and the Comparative Examples are shown in thefollowing Table 1.

TABLE 1 Flame retarder Resins to be made flame retardant (wt %) ContentPC ABS HIPS AS PET PLA Sort (wt %) Ex. 1 99.8 — — — — — Inv. Sp. 2 0.1Ex. 2 84.3 15.0 — — — — Inv. Sp. 1 0.1 Ex. 3 89.2 — 10.0 — — — Inv. Sp.3 0.5 Ex. 4 89.5 — — 10.0 — — Inv. Sp. 1 0.2 Ex. 5 84.0 — — — 15.0 —Inv. Sp. 2 0.2 Ex. 6 48.8 — — — — 50.0 Inv. Sp. 2 0.5 Comp. Ex. 1 99.8 —— — — — Ctl. Sp. 1 0.1 Comp. Ex. 2 99.8 — — — — — Ctl. Sp. 2 0.1 Comp.Ex. 3 99.8 — — — — — Ctl. Sp. 3 0.1 Comp. Ex. 4 84.3 15.0 — — — — Ctl.Sp. 2 0.1 Comp. Ex. 5 89.2 — 10.0 — — — Ctl. Sp. 1 0.5 Comp. Ex. 6 89.5— — 10.0 — — Ctl. Sp. 3 0.2 Comp. Ex. 7 84.0 — — — 15.0 — Ctl. Sp. 2 0.2Comp. Ex. 8 48.8 — — — — 50.0 Ctl. Sp. 1 0.5 Test on Flame appearanceafter retarder (IS) Anti-drip storage at high (wt %) agent (wt %) Teston combustibility (UL94) temperature Ex. 1 — 0.1 V-0 prescription passed∘ Ex. 2 0.5 0.1 V-0 prescription passed ∘ Ex. 3 — 0.3 V-0 prescriptionpassed ∘ Ex. 4 0.1 0.2 V-0 prescription passed ∘ Ex. 5 0.5 0.3 V-0prescription passed ∘ Ex. 6 0.5 0.2 V-1 prescription passed ∘ Comp. Ex.1 — 0.1 V-1 prescription/not passed ∘ Comp. Ex. 2 — 0.1 V-1prescription/not passed ∘ Comp. Ex. 3 — 0.1 V-0 prescription passed xComp. Ex. 4 0.5 0.1 V-1 prescription/not passed ∘ Comp. Ex. 5 — 0.3 V-1prescription/not passed ∘ Comp. Ex. 6 0.1 0.2 V-0 prescription passed xComp. Ex. 7 0.5 0.3 V-1 prescription/not passed x Comp. Ex. 8 0.5 0.2V-2 prescription/not passed ∘

It is seen from the results of evaluation of Table 1 that the Example 1,containing acrylonitrile units in the flame retarder, is superior inflame retardant properties to the Comparative Examples 1 and 2 notcontaining acrylonitrile units in the flame retarder.

It is also seen from the results of evaluation of Table 1 that, in caseof the Comparative Example 3, in which amide or carboxyl groups, liableto take up water, are present in the flame retarder, the flame retardantresin composition is susceptible to changes with lapse of time, onprolonged storage, such as changes in color, specifically, speckledpoints, indicating water take-up by the polymer, to detract from theappearance, even though flame retardant properties may be afforded tosome extent to the flame retardant resin composition.

It is also seen from the results of evaluation of Table 1 that, ascompared to the Comparative Examples 4 to 8, containing control samples,not conforming to the present invention, as the flame retarder, theExamples 2 to 6, containing the inventive samples as the flame retarder,represent a flame retardant resin composition in which high flameretardant properties and good appearance are achieved simultaneously.

It is seen from above that, in preparing a flame retardant resincomposition, use of an acrylonitrile-styrene based polymer, in whichsulfonic acid groups have been introduced by sulfonating processing witha sulfonating agent with water content less than 3 wt %, as a flameretarder, is crucial in preparing the flame retardant resin compositionon which flame retardant properties have been conferred adequately suchthat deficiencies in appearance are not produced even on prolongedstorage.

A modified embodiment of the flame retarder according to the presentinvention and the flame retardant resin composition containing thisflame retarder will now be explained.

The flame retardant resin composition of the present embodiment is aresin material, used for example in household electrical appliances,cars, office utensil, stationeries, groceries, building materials or infibers. The flame retarder is contained in a resin composition, which isto be made flame retardant, for conferring flame retardant properties onthe composition.

The flame retarder, contained in the flame retardant resin composition,is composed of an aromatic polymer, into which preset amounts ofsulfonic acid groups and/or sulfonate groups have been introduced. Thearomatic polymer contains 1 mol % to 100 mol % of monomer units, eachhaving an aromatic skeleton, and has a weight average molecular weightranging between 25000 and 10000000 into which preset amounts of sulfonicacid groups and/or sulfonates have been introduced. The aromaticskeleton of the aromatic polymer, contained in the flame retarder, maybe contained in a side chain or in the main chain of the polymer.

Specifically, the aromatic polymer, having the aromatic skeleton in itsside chain, may be enumerated by, for example, polystyrene (PS), highimpact polystyrene (HIPS: styrene-butadiene copolymer), anacrylonitrile-styrene copolymer (AS), an acrylonitrile-butadiene-styrenecopolymer (ABS), an acrylonitrile-chlorinated polyethylene-styrene resin(ACS), an acrylonitrile-styrene-acrylate copolymer (ASA), anacrylonitrile-ethylene-propylene rubber-styrene copolymer (AES) and anacrylonitrile-ethylene-propylene-diene-styrene resin (AEPDMS). These maybe used either alone or in combination.

The aromatic polymer, having an aromatic skeleton in its main chain, maybe enumerated by, for example, a polycarbonate (PC), polyphenylene oxide(PPO), polyethylene terephthalate (PET), polybutylene terephthalate(PBT), and polysulfone (PSF). These may be used either alone or incombination. The aromatic polymer, having an aromatic skeleton in itsmain chain, may also be used as a mixture (alloy) with e.g. otherresin(s). Specifically, the alloy with the other resin(s) may beenumerated by an ABS/PC alloy, a PS/PC alloy, an AS/PC alloy, an HIPS/PCalloy, a PET/PC alloy, a PBT/PC alloy, a PVC/PC alloy, a PLA(poly-lactic acid)/PC alloy, a PPO/PC alloy, a PS/PPO alloy, an HIPS/PPOalloy, an ABS/PET alloy and a PET/PBT alloy. These may be used eitheralone or in combination.

In the aromatic polymer, the content of the monomer units, havingaromatic skeletons, is in a range from 1 mol % to 100 mol %, preferablyin a range from 30 mol % to 100 mol % and more preferably in a rangefrom 40 mol % to 100 mol %.

If the content of the monomer units, having aromatic skeletons, is lessthan 1 mol %, the flame retarder becomes difficult to dispersesubstantially evenly in the resin which should be made flame retardant,or the rate of the sulfonic acid groups or the sulfonate groupsintroduced into the aromatic polymer becomes lower. Hence, flameretardant properties cannot be conferred appropriately on the flameretardant resin composition.

Most typical of the aromatic skeletons, making up the aromatic polymer,are an aromatic hydrocarbon, an aromatic ester, an aromatic ether(phenols), an aromatic thioether (thiophenols), an aromatic amide, anaromatic imide, an aromatic amidimide, an aromatic ether imide, anaromatic sulfone and an aromatic ether sulfone. Of these, the aromaticether sulfone is most illustrative, and may be exemplified by thosehaving a ring structure, such as benzene, naphthalene, anthracene,phenathrene and coronene. Of these aromatic skeletons, a benzene ringstructure or an alkylbenzene ring structure is most common.

Although not limitative, the monomer units, other than the aromaticskeleton, contained in the aromatic polymer, may be enumerated by, forexample, acrylonitrile, butadiene, isoprene, pentadiene,cyclopentadiene, ethylene, propylene, butene, isobutylene, vinylchloride, α-methylstyrene, vinyl toluene, vinyl naphthalene, acrylicacid, acrylate, methacrylic acid, methacrylate, maleic acid, fumaricacid and ethylene glycol, which may be used either alone or incombination.

The weight average molecular weight of the aromatic polymer is in arange between 25000 and 10000000, preferably in a range between 30000and 1000000 and more preferably in a range between 50000 and 500000.

If the weight average molecular weight of the aromatic polymer deviatesfrom 25000 and 10000000, it becomes difficult to disperse the flameretarder substantially evenly in the resin which should be made flameretardant, that is, compatibility of the polymer is lowered, with theconsequence that flame retardant properties cannot be properly conferredon the flame retardant resin composition.

When the weight average molecular weight of the aromatic polymer is inthe range between 25000 and 10000000, the polymer is improved incompatibility with respect to the resin which is to be rendered flameretardant, and hence the polymer may be dispersed substantially evenlyin the resin. Thus, flame retardant properties may be conferredsubstantially evenly and properly on the flame retardant resincomposition. Meanwhile, the weight average molecular weight of thearomatic polymer may readily be obtained by measurement methods, such asmethods of measurement of the photometric GPC (gel permeationchromatography), employing known molecular weight samples (standardproducts), measurement of the viscosity of the solution or measurementof light scattering.

As the aromatic polymer, used-up redeemed materials or scraps from theplant may be used. That is, low cost may be arrived at through use of aredeemed material as a feedstock material.

The sulfonic acid groups and/or sulfonate groups may be introduced in apreset amount into the above-described aromatic polymer to give a flameretarder contained in the resin which is to be rendered flame retardant,whereby high flame retardant properties may be conferred on the resin.The method for introducing the sulfonic acid groups and/or sulfonategroups into the aromatic polymer may be exemplified by a method ofsulfonating the aromatic polymer with a sulfonating agent.

The sulfonating agent, used for sulfonating the aromatic polymer, ispreferably such agent containing less than 3 wt % of moisture.Specifically, the sulfonating agent is one or more selected from thegroup consisting of sulfuric anhydride, fuming sulfuric acid,chlorosulfonic acid and polyalkylbenzene sulfonic acid. The sulfonatingagents used may also be complexes with a Lewis base of, for example, analkyl phosphate or dioxane.

If concentrated sulfuric acid, with the water content of 96 wt %, isused as a sulfonating agent, the cyano groups in the polymer arehydrolyzed and converted to amide or carboxylic groups, having a highhygroscopic effect, at the time of sulfonating processing of thearomatic polymer for preparation of the flame retarder. Hence, the flameretarder containing these amide or carboxylic groups is prepared. If theflame retarder, containing larger quantities of the amide or carboxylicgroups, is used, high flame retardant properties may be conferred on theflame retardant resin composition. There is however a fear that themoisture may be taken up from outside with lapse of time, so that theflame retardant resin composition may be discolored to detract from theappearance. Or, the flame retardant resin composition is deteriorated inphysical properties. Specifically, the polystyrene sulfonate flameretarder, proposed in JP Laid-Open Patent Publication 2001-2941, belongsto this sort of the flame retarder.

In light of the above, a method consisting in adding a preset quantityof a sulfonating agent to a solution of an aromatic polymer in anorganic solvent (chlorine-based solvent) to carry out reaction, may bementioned as another method of sulfonating the aromatic polymer. Thereis also a method consisting in adding a preset amount of a presetsulfonating agent to a solution obtained on dispersing a pulverulentaromatic polymer in, for example an organic solvent, with the polymernot being dissolved in the solvent, in order to carry out reaction.There are furthermore a method consisting in directly charging anaromatic polymer in a sulfonating agent to carry out reaction, and amethod consisting in directly spraying a sulfonating gas, specifically agas of sulfuric anhydride (SO₃), to the pulverulent aromatic polymer tocarry out reaction. Of these, the method consisting in directly sprayingthe sulfonating gas to the pulverulent aromatic polymer without usingorganic solvents is most preferred.

Into the acrylonitrile-styrene based polymer, the sulfonic acid groups(—SO₃H) or the sulfonate groups are introduced either directly or asthese groups have been neutralized with ammonia or amine compounds.Specified examples of the sulfonate groups include Na, K, Li, Ca, Mg,Al, Zn, Sb and Sn salt groups of sulfonic acid.

It is noted that higher flame retardant properties may be conferred onthe flame retardant resin composition when sulfonate groups, rather thanthe sulfonic acid groups, are introduced into the aromatic polymer. Ofthe sulfonate groups, the Na, K, and Ca salt groups are preferred.

The rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer may be adjusted by the amount ofaddition of the sulfonating agent, the time of reaction of thesulfonating agent, reaction temperature or the kind as well as theamount of the Lewis bases. Of these, the amount of addition of thesulfonating agent, the time of reaction of the sulfonating agent and thereaction temperature are most preferred to use for adjustment.

Specifically, the rate of the sulfonic acid groups and/or the sulfonategroups introduced into the aromatic polymer as sulfur contents is 0.001wt % to 20 wt %, preferably 0.01 wt % to 10 wt % and more preferably 0.1wt % to 5 wt %.

In case the rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer as sulfur contents is lower than0.001 wt %, the flame retardant components are decreased, and hence itbecomes difficult to confer flame retardant properties on the flameretardant resin composition. If conversely the rate of the sulfonic acidgroups and/or the sulfonate groups introduced into the aromatic polymeras sulfur contents is more than 20 wt %, the flame retardant resincomposition is susceptible to changes with lapse of time (absorption ofwater), or the blooming time during combustion tends to be prolonged.

The rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer may readily be determined byquantitative analysis, by e.g. a combustion flask method, of the sulfur(S) contents in the sulfonated aromatic polymer, as an example.

The resin to be rendered flame retardant, that is, the resin whichproves a feedstock material of the resin composition on which flameretardant properties are to be conferred by the above-described flameretarder contained therein, that is, the flame retardant resincomposition, may be enumerated by, for example, polycarbonate (PC), anacrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), anacrylonitrile-styrene copolymer (AS), polyvinyl chloride (PVC),polyphenylene oxide (PPO), polyethylene terephthalate (PET),polyethylene butylate (PBT), polysulfone (PSF), thermoplastic elastomer(TPE), polybutadiene (PB), polyisoprene (PI), nitrile rubber(acrylonitrile-butadiene rubber), nylon and poly-lactic acid (PLA).These may be used either alone or in combination.

The resins to be most effectively rendered flame retardant by containingthe aforementioned flame retarder may be enumerated by, for example, PC,ABS, (HI)PS, AS, PPO, PBT, PET, PVC, PLA, ABS/PC alloy, PS/PC alloy,AS/PC alloy, HIPS/PC alloy, PET/PC alloy, PBT/PC alloy, PVC/PC alloy,PLA (poly-lactic acid)/PC alloy, PPO/PC alloy, PS/PPO alloy, HIPS/PPOalloy, ABS/PET alloy and PET/PBT alloy. These may be used either aloneor in combination.

Since the flame retarder used is an aromatic polymer having a weightaverage molecular weight ranging between 25000 and 10000000, andcontaining sulfonic acid groups and/or sulfonate groups, introducedtherein, it is possible to proliferate the sorts of the resins which areto be made flame retardant.

As the resins to be rendered flame retardant, used-up redeemed materialsor scraps from the plant may be used. That is, low cost may be arrivedat through use of a redeemed material as a feedstock material.

In the above-described flame retardant resin composition, in which thearomatic polymer, having the weight average molecular weight is in arange from 25000 to 10000000, and containing a preset amount of sulfonicacid groups and/or sulfonate groups, introduced therein, is used as aflame retarder, the flame retarder may be improved in compatibility withrespect to the resin to be rendered flame retardant, so that flameretardant properties may properly be conferred on the resin.

Moreover, the flame retarder, contained in the flame retardant resincomposition, is obtained by sulfonating the aromatic polymer, having theweight average molecular weight in a range from 25000 to 10000000, witha sulfonating agent, having the water content less than 3 wt %, so thatamide or carboxylic groups, having a high hygroscopic effect, may besuppressed from being introduced into the flame retarder. Hence, thereis only little possibility of the flame retarder taking up the moisturein atmospheric air during prolonged storage becoming discolored todetract from appearance, or the flame retarder being lowered inmechanical strength.

In the present flame retardant resin composition, the content of theflame retarder is in a range from 0.0001 wt % to 30 wt %, preferably ina range from 0.001 wt % to 10 wt.% and more preferably in a range from0.01 to 5 wt %.

In case the content of the flame retarder is less than 0.0001 wt %, itbecomes difficult to confer flame retardant properties on the flameretardant resin composition. If, on the other hand, the content of theflame retarder is more than 30 wt %, a reverse effect is presented, thatis, the resin composition to be rendered flame retardant is moresusceptible to combustion.

That is, the present flame retarder is to be added in a minor quantityto the resin, which is to be rendered flame retardant, to yield a flameretardant resin composition on which the flame retardant properties havebeen conferred effectively.

In the flame retardant resin composition, described above, known flameretarders, for example, may be admixed, in addition to theaforementioned flame retarders, for further improving the flameretardant properties.

These known flame retarders may be enumerated by, for example, organicphosphate or phosphite based flame retarders, halogenated phosphatebased flame retarders, inorganic phosphorus based flame retarders,halogenated bisphenol based flame retarders, halogen compound basedflame retarders, antimony based flame retarders, nitrogen based flameretarders, boron based flame retarders, metal salt based flameretarders, inorganic flame retarders and silicon based flame retarders.These may be used either alone or in combination.

Specifically, the organic phosphate or phosphite based flame retardersmay be enumerated by, for example, triphenyl phosphate, methyl neobenzylphosphate, pentaerythritol diethyl diphosphate, methyl neopentylphosphate, phenyl neopentyl phosphate, pentaerythritol diphenylphosphate, dicyclopentyl hypodiphosphate, dineopentyl hypophosphite,phenyl pyrocatechol phosphite, ethyl pyrocatechol phosphate anddipyrocatechol hypodiphosphate. These may be used either alone or incombination.

The halogenated phosphate based flame retarders may be enumerated by,for example, tris(β-chloroethyl)phosphate,tris(dichloropropyl)phosphate, tris(β-bromoethyl)phosphate,tris(dibromopropyl)phosphate, tris(chloropropyl)phosphate,tris(dibromophenyl)phosphate, tris(tribromophenyl)phosphate,tris(tribromoneopentyl)phosphate, condensed polyphosphate and condensedpolyphosphonate. These may be used either alone or in combination.

The inorganic phosphorus based flame retarders may be exemplified by redphosphorus and inorganic phosphates, which may be used either alone orin combination.

The halogenated bisphenol based flame retarders may be exemplified bytetrabromo bisphenol A, oligomers thereof, andbis(bromoethylether)tetrabromo bisphenol A, which may be used eitheralone or in combination.

The halogen compound based flame retarders may be enumerated by, forexample, decabromo diphenylether, hexabromobenzene, hexabromocyclododecane, tetrabromo phthalic anhydride, (tetrabromobisphenol)epoxyoligomers, hexabromo biphenylether, tribromophenol, dibromocresylglycidyl ether, decabromo diphenyl oxides, halogenated polycarbonates,halogenated polycarbonate copolymers, halogenated polystyrene,halogenated polyolefin, chlorinated paraffin and perchloro cyclodecane,which may be used either alone or in combination.

The antimony based flame retarders may be enumerated by, for example,antimony trioxide, antimony tetroxide, antimony pentoxide and sodiumantimonate. These may be used either alone or in combination.

The nitrogen-based flame retarders may be enumerated by, for example,melamine, alkyl group or aromatic group substituted melamine, melaminecyanurate, melamine isocyanurate, melamine phosphate, triazine,guanidine compounds, urea, various cyanuric acid derivatives, andphosphasene compounds. These may be used either alone or in combination.

The boron based flame retarders may be enumerated by, for example, zincborate, zinc metaborate and barium metaborate. These may be used eitheralone or in combination.

The metal salt based flame retarders may be enumerated by, for example,alkyl metal salts or alkyl earth metal salts of perfluoroalkane sulfonicacids, alkylbenzene sulfonic acids, halogenated alkylbenzene sulfonicacids, alkylsulfonic acids and naphthalene sulfonic acid. These may beused either alone or in combination.

The inorganic flame retarders may be enumerated by, for example,magnesium hydroxide, aluminum hydroxide, barium hydroxide, calciumhydroxide, dolomite, hydrotalcite, basic magnesium carbonates, zirconiumhydroxide and hydrates of inorganic metal compounds, such as hydrates oftin oxide, metal oxides, such as aluminum oxide, iron oxide, titaniumoxide, manganese oxide, magnesium oxide, zirconium oxide, zinc oxide,molybdenum oxide, cobalt oxide, bismuth oxide, chromium oxide, tinoxide, nickel oxide, copper oxide and tungsten oxide, powders of metals,such as aluminum, iron, copper, nickel, titanium, manganese, tin, zinc,molybdenum, cobalt, bismuth, chromium, tungsten and antimony, andcarbonates, such as zinc carbonates, magnesium carbonate, calciumcarbonate and barium carbonate. These may be used either alone or incombination.

Of the inorganic flame retarders, magnesium hydroxide, aluminumhydroxide, talc, which is a hydrated magnesium silicate, basic magnesiumcarbonate, mica, hydrotalcite, and aluminum are preferred from theperspective of flame retardant properties and from economicconsiderations. Meanwhile, used-up redeemed materials or scraps from theplant may be used as the inorganic flame retarders.

The silicon-based flame retarders may be exemplified by, for example,polyorganosiloxane resins (silicone or organic silicates) and silica,which may be used either alone or as a mixture. The polyorganosiloxaneresins may be enumerated by, for example, polymethylethyl siloxaneresin, polydimethyl siloxane resin, polymethyl phenyl siloxane resin,polydiphenyl siloxane resin, polydiethyl siloxane resin, polyethylphenyl siloxane resin and mixtures thereof.

The alkyl moiety portions of these polyorganosiloxane resins may containfunctional groups, for example, an alkyl group, an alkoxy group, ahydroxy group, an amino group, a carboxyl group, a silanol group, amercapto group, an epoxy group, a vinyl group, an aryloxy group, apolyoxyalkylene group, a hydroxy group or halogens. Of these, the alkylgroup, alkoxy group, hydroxy group and the vinyl groups are mostpreferred.

The polyorganosiloxane resins are of the average molecular weight notless than 100, preferably in a range from 500 to 5000000, and are in theform of oil, varnish, gum or pellets. As for silica, it is desirablysurface-processed with a silane coupling agent of a hydrocarboncompound.

The content of the known common flame retarders, given hereinabove, isusually in a range from 0.001 wt % to 50 wt %, preferably in a rangefrom 0.01 wt % to 30 wt % and more preferably in a range from 0.1 wt %to 10 wt %, referred to the resin to be rendered flame retardant,depending on the sort of the flame retarder, the level of flameretardant properties or on the sort of the resin to be rendered flameretardant.

In the flame retardant resin composition, known routine inorganicfillers may be mixed, in addition to the above-mentioned flameretarders, for improving mechanical strength or for further improvingflame retardant properties.

Among the known inorganic fillers, there are, for example, crystallinesilica, fused silica, alumina, magnesia, talc, mica, kaolin, clay,diatomaceous earth, calcium silicate, titanium silicate, titanium oxide,glass fibers, calcium fluoride, calcium sulfate, barium sulfate, calciumphosphate, carbon fibers, carbon nanotubes and potassium titanatefibers. These may be used either alone or as a mixture. Of theseinorganic fillers, talc, mica, carbon, glass and carbon nanotubes aremost preferred.

The inorganic fillers are contained in the flame retardant resincomposition in an amount in a range from 0.1 wt % to 90 wt %, preferablyin a range from 0.5 wt % to 50 wt % and more preferably in a range from1 wt % to 30 wt %.

If the content of the inorganic filler is less than 0.1 wt %, the effectof improving the toughness or the flame retardant properties of theflame retardant resin composition is lowered. If conversely the contentof the inorganic filler is higher than 90 wt %, such inconveniences mayarise that, in injection molding the flame retardant resin composition,the flame retardant resin composition in a molten state is lowered influidity or in mechanical strength.

Furthermore, in the flame retardant resin composition, fluoro olefinresins, for example, may be mixed, in addition to the above-mentionedflame retarders, for suppressing the dripping phenomenon at the time ofthe combustion.

Among the fluoro olefin resins, capable of suppressing the drippingphenomenon, there are, for example, a difluoroethylene polymer, atetrafluoroethylene polymer, a tetrafluoroethylene-hexafluoropropylenecopolymer and a copolymer of tetrafluoroethylene with an ethylenemonomer. These may be used either alone or in combination.

Of these fluoro olefin resins, tetrafluoroethylene polymers are mostpreferred. The average molecular weight of the tetrafluoroethylenepolymers is not less than 50000 and preferably in a range from 100000 to20000000. Meanwhile, the fluoro olefin resins, exhibiting fibril formingproperties, are more preferred.

The fluoro olefin resins are contained in a range from 0.001 wt % to 5wt %, preferably in a range from 0.005 wt % to 2 wt % and morepreferably in a range from 0.01 wt % to 0.5 wt %.

If the content of the fluoro olefin resins is less than 0.001 wt %, itbecomes difficult to suppress the dripping phenomenon. If conversely thecontent of the fluoro olefin resins is more than 5 wt %, the effect insuppressing the dripping phenomenon becomes saturated, so that there mayarise such inconveniences that the cost is elevated or the mechanicalstrength is lowered.

In the flame retardant resin composition, there may be added, inaddition to the above-mentioned flame retardants, anti-oxidants(phenolic, phosphorus based or sulfur based anti-oxidants), anti-staticagents, UV absorbers, photo-stabilizers, plasticizers, compatibilitypromoting agents, colorants (pigments or dyestuffs), bactericidalagents, hydrolysis inhibiting agents or surface processing agents forimproving injection molding properties, shock-proofing properties,appearance, thermal resistance, weatherability or toughness.

In preparing the above-mentioned flame retardant resin composition, aflame retarder, a resin to be rendered flame retardant, and otheradditives, are dispersed substantially evenly in a kneader, such as atumbler, a reblender, a mixer, an extruder or a co-kneader. Theresulting product is molded by molding methods, such as injectionmolding, injection compression molding, extrusion molding, blow molding,vacuum molding, press molding, foam molding or supercritical molding tomold the composition in a preset shape.

The molded product, formed of the flame retardant resin composition, isused in various fields as enclosures or component parts of variousproducts exhibiting flame retardant properties, such as householdelectrical appliances, cars, information equipment, office utensils,telephone sets, stationeries, furniture or fibers.

The present invention will now be described with reference to Examplesand Comparative Examples for comparison to the Examples.

First, inventive samples and control samples of flame retarders,contained in the Examples and Comparative Examples, were prepared.

(Inventive Sample 4)

In preparing the inventive sample 4, 2.6 g of a styrene homopolymer,with a weight average molecular weight of 250000, as measured withphotometric GPC, as an aromatic polymer, were charged into around-bottomed flask, into which were previously charged 23.4 g of1,2-dicycloethane. The reaction system was dissolved by heating to 50°C. to prepare a polymer solution. A liquid mixture of 0.5 g of 98%sulfuric acid and 0.6 g of acetic anhydride was dripped over ten minuteson the polymer solution. After the end of the dripping, the resultingmass was cured for four hours, by way of sulfonating the aromaticpolymer. The reaction liquid was poured into boiling pure water toremove the solvent to yield a solid substance. This solid substance wasrinsed thrice with lukewarm pure water and dried under reduced pressureto yield a dried solid substance.

The solid substance obtained was put to elementary analysis by acombustion flask method. The sulfur content in the so obtained flameretarder was found to be 3.9 wt %, that is, the rate of sulfonic acidintroduced was 14 mol %.

The dried solid substance was neutralized with potassium hydroxide andagain dried to prepare a flame retarder. That is, the inventive sample 4is an aromatic polymer with a weight average molecular weight of 250000into which were introduced sulfonate groups.

(Inventive Sample 5)

In preparing the inventive sample 5, a used transparent window materialof an 8 mm cassette, as an aromatic polymer, was pulverized to formpowders with 83 mesh pass size. 3 g of the powdered material, which isformed of an acrylonitrile-styrene copolymer resin (acrylonitrile unit:43 mol %; styrene unit: 57 mol %), with a weight average molecularweight of 120000, as measured with photometric GPC, was charged into around-bottomed flask. An SO₃ gas, evolved from 4 g of fuming sulfuricacid, was blown at room temperature over four hours into the powderedmaterial, which was kept in an agitated state, by way of sulfonating thearomatic polymer. Air was then sent into the flask to remove residualSO₃ gas from the round-bottomed flask. The solid substance was washedthrice with water and subsequently dried.

The solid substance obtained was put to elementary analysis by acombustion flask method. The sulfur content in the so obtained flameretarder was found to be 2.1 wt %, that is, the rate of sulfonic acidintroduced was 9.4 mol %.

The dried solid substance was then neutralized with sodium hydroxide andagain dried to yield a flame retarder. That is, the inventive sample 5is formed of an aromatic polymer, with a weight average molecular weightof 120000, into which were introduced sulfonate groups.

(Inventive Sample 6)

In the inventive sample 6, sodium polystyrene sulfonate, with a weightaverage molecular weight of 70000 (sulfur content: 14.1 wt %) us used asa flame retarder.

(Inventive Sample 7)

In the inventive sample 7, sodium polystyrene sulfonate, with a weightaverage molecular weight of 500000 (sulfur content of 13.9 wt %) wasused as a flame retarder.

(Inventive Sample 8)

In the inventive sample 8, a flame retarder, formed of a white solidsubstance, was prepared in the same way as in the above inventive sample5, except using powdered polycarbonate, obtained on pulverizing aredeemed MD disc from the plant, to 83 mesh pass size, as an aromaticpolymer. The polycarbonate was of the weight averaged molecular weightof 31000, as measured with photometric GPC. That is, the inventivesample 8 is the aromatic polymer, with a weight averaged molecularweight of 31000, into which were introduced sulfonate groups. The sulfurcontent in the flame retarder, thus prepared, was measured in the sameway as in the inventive sample 4. The sulfur content was found to be0.31 wt %.

(Inventive Sample 9)

In the inventive sample 9, a flame retarder, as a brown sold substance,was prepared in the same way as in the inventive sample 5, except usingpowdered poly(2,6-dimethyl-p-phenylene oxide), in the powdered form, asan aromatic polymer, with a weight average molecular weight of 50000, asmeasured with photometric GPC. That is, the inventive sample 9 is anaromatic polymer, with a weight average molecular weight of 50000, intowhich were introduced sulfonate groups. The sulfur content in the flameretarder, thus prepared, was measured in the same way as in theinventive sample 4. The sulfur content was found to be 2.3 wt %.

(Control Sample 4)

In the control sample 4, a flame retarder was obtained in the same wayas in the above inventive sample 4, except using polystyrene with theweight average molecular weight of 9000 as an aromatic polymer. That is,the control sample 4 is the aromatic polymer, with the weight averagemolecular weight of 9000, into which were introduced sulfonate groups.The sulfur content in the flame retarder, thus prepared, was measured inthe same way as in the inventive sample 4. The sulfur content was foundto be 4.1 wt %.

(Control Sample 5)

In the control sample 5, a flame retarder was obtained in the same wayas in the above inventive sample 5, except using polystyrene with theweight average molecular weight of 20000 as an aromatic polymer. Thatis, the control sample 4 is the aromatic polymer, with the weightaverage molecular weight of 20000, into which were introduced sulfonategroups. The sulfur content in the flame retarder, thus prepared, wasmeasured in the same way as in the inventive sample 4. The sulfurcontent was found to be 2.0 wt %.

(Control Sample 6)

In the control sample 6, sodium polystyrene sulfonate with the weightaverage molecular weight of 18000 (sulfur content: 14 wt %) was used asa flame retarder.

The inventive samples 4 to 9 and the control samples 4 to 6, obtained asdescribed above, that is, flame retarders, were introduced into presetresin which is to be made flame retardant, to prepare Examples andComparative Examples.

EXAMPLE 7

In the Example 7, 99.8 parts by weight of a bisphenol A polycarbonateresin, referred to below as PC, as a resin to be made flame retardant,0.1 part by weight of the inventive sample 4, as a flame retarder, and0.1 part by weight of fibril-forming polytetrafluoroethylene, referredto below as PTFE, as an anti-drip agent, were mixed together to form aflame retardant resin precursor. This flame retardant resin precursorwas supplied to an injection molding apparatus and injection molded at apreset temperature to form a strip-shaped test piece, 1.5 mm inthickness, formed of the flame retardant resin composition.

EXAMPLE 8

In the Example 8, a strip-shaped test piece was prepared in the same wayas in Example 1, except mixing 99.8 parts by weight of PC, as a resin tobe made flame retardant, 0.1 part by weight of the inventive sample 5,as a flame retarder, and 0.1 part by weight of PTFE, as an anti-dripagent, to form a flame retardant resin precursor.

EXAMPLE 9

In the Example 9, a strip-shaped test piece was prepared in the same wayas in Example 7, except mixing 99.4 parts by weight of PC, as a resin tobe made flame retardant, 0.5 part by weight of the inventive sample 6,as a flame retarder, and 0.1 part by weight of PTFE, as an anti-dripagent, to form a flame retardant resin precursor.

EXAMPLE 10

In the Example 10, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 99.4 parts by weight of PC, as aresin to be made flame retardant, 0.5 part by weight of the inventivesample 7, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to form a flame retardant resin precursor.

EXAMPLE 11

In the Example 11, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 99.85 parts by weight of PC, as aresin to be made flame retardant, 0.05 part by weight of the inventivesample 8, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to form a flame retardant resin precursor.

EXAMPLE 12

In the Example 12, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 84 parts by weight of PC and 15 partsby weight of an acrylonitrile-butadiene-styrene copolymer resin,referred to below as ABS resin (weight ratio ofacrylonitrile/polybutadiene/styrene=24/20/56), as resins to be madeflame retardant, 0.4 part by weight of the inventive sample 5, as aflame retarder, 0.4 part by weight of polymethyl phenyl siloxane, whichis a silicon-based flame retarder, referred to below as SI, as anotherflame retarder, and 0.2 part by weight of PTFE, as an anti-drip agent,to prepare a flame retardant resin precursor.

EXAMPLE 13

In the Example 13, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 89 parts by weight of PC and 10 partsby weight of a rubber-modified polystyrene, referred to below as HIPSresin (weight ratio of polybutadiene/styrene=10/90), as resins to bemade flame retardant, 0.5 part by weight of the inventive sample 5, as aflame retarder, 0.3 part by weight of SI, as another flame retarder, and0.2 part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

EXAMPLE 14

In the Example 13, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 84 parts by weight of PC and 15 partsby weight of polyethylene terephthalate, referred to below as PET, asresins to be made flame retardant, 0.4 part by weight of the inventivesample 4, as a flame retarder, 0.4 part by weight of SI, as anotherflame retarder, and 0.2 part by weight of PTFE, as an anti-drip agent,to prepare a flame retardant resin precursor.

EXAMPLE 15

In the Example 15, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 49 parts by weight of PC and 50 partsby weight of poly-lactic acid, referred to below as PLA, as resins to bemade flame retardant, 0.3 part by weight of the inventive sample 8, as aflame retarder, 0.4 part by weight of SI, as another flame retarder, and0.3 part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

EXAMPLE 16

In the Example 16, a strip-shaped test piece was prepared in the sameway as in Example 7, except mixing 89 parts by weight of PC and 10 partsby weight of the HIPS resin, as resins to be made flame retardant, 0.3part by weight of the inventive sample 9, as a flame retarder, 0.4 partby weight of SI, as another flame retarder, and 0.3 part by weight ofPTFE, as an anti-drip agent, to prepare a flame retardant resinprecursor.

COMPARATIVE EXAMPLE 9

In the Comparative Example 9, a strip-shaped test piece was prepared inthe same way as in Example 7, except mixing 99.8 parts by weight of PC,as a resin to be made flame retardant, 0.1 part by weight of the controlsample 4, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 10

In the Comparative Example 10, a strip-shaped test piece was prepared inthe same way as in Example 7, except mixing 99.8 parts by weight of PC,as a resin to be made flame retardant, 0.1 part by weight of the controlsample 2, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 11

In the Comparative Example 11, a strip-shaped test piece was prepared inthe same way as in Example 1, except mixing 99.4 parts by weight of PC,as a resin to be made flame retardant, 0.5 part by weight of the controlsample 6, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 12

In the Comparative Example 12, a strip-shaped test piece was prepared inthe same way as in Example 7, except mixing 84 parts by weight of PC and15 parts by weight of an ABS resin, as resins to be made flameretardant, 0.4 part by weight of the control sample 1, as a flameretarder, 0.4 part by weight of SI, as another flame retarder, and 0.2part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

COMPARATIVE EXAMPLE 13

In the Comparative Example 13, a strip-shaped test piece was prepared inthe same way as in Example 7, except mixing 89 parts by weight of PC and10 parts by weight of a HIPS resin, as resins to be made flameretardant, 0.5 part by weight of the control sample 2, as a flameretarder, 0.3 part by weight of SI, as another flame retarder, and 0.2part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

COMPARATIVE EXAMPLE 14

In the Comparative Example 14, a strip-shaped test piece was prepared inthe same way as in Example 7, except mixing 84 parts by weight of PC and15 parts by weight of PET, as resins to be made flame retardant, 0.4part by weight of the control sample 3, as a flame retarder, 0.4 part byweight of SI, as another flame retarder, and 0.2 part by weight of PTFE,as an anti-drip agent, to prepare a flame retardant resin precursor.

Then, tests on combustibility were conducted on the Examples and theComparative Examples thus obtained.

The tests on combustibility were conducted as perpendicularcombustibility tests in accordance with V-0, V-1 and V-2 prescriptionsof UL 94 (Underwriters' Laboratory Subject 94). Specifically, five testpieces each of the Examples and the Comparative Examples were provided,and a burner flame was applied to each of the strip-shaped test piecessupported substantially upright. This state was maintained for tenseconds and thereafter the burner flame was separated from the testpieces. When the flame was extinguished, the burner flame was appliedfor further ten seconds, after which the burner flame was separated fromthe test pieces. Decision was given at this time on the basis of the sumof the time duration of combustion with flame after the end of the firstflame contact with the test pieces, the time duration of combustion withflame after the end of the second flame contact with the test pieces,the time duration of combustion with flame after the end of the secondflame contact with the test pieces, and the time duration of combustionwithout flame after the end of the second flame contact with the testpieces, the sum of time durations of combustion with flame of the fivetest pieces, and the presence/absence of the droppings of combustion.The V-0 prescription provides that combustion with flame shall come to aclose within ten seconds for the first and second combustion events. TheV-1 and V-2 prescriptions provide that combustion with flame shall cometo a close within 30 seconds for the first and second combustion events.The sum of the time duration of the second combustion with flame and thetime duration of the second combustion without flame is less than 30seconds for the V-0 prescription, while the same sum for the V-1 and V-2prescriptions is less than 60 seconds. The sum of the time durations ofcombustion with flame of the five test pieces is less than 50 secondsfor the V-0 prescription, while the same sum for the V-1 and V-2prescriptions is less than 250 seconds. The droppings of combustion aretolerated only for the V-2 prescription. That is, with the UL combustiontest method (UL 94), the flame retardant properties become higher in theorder of the V-0, V-1 and V-2.

In the following Table 2, the results of evaluation on tests oncombustibility in the Examples and Comparative Examples are shown.

TABLE 2 Resins to be made flame retardant PC ABS HIPS PET PLA Ex. 7 99.8— — — — Ex. 8 99.8 — — — — Ex. 9 99.4 — — — — Ex. 10 99.4 — — — — Ex. 1199.85 — — — — Ex. 12 84.0 15 — — — Ex. 13 89.0 — 10 — — Ex. 14 84.0 — —15 — Ex. 15 49.0 — — — 50 Ex. 16 89.0 — 10 — — Comp. Ex. 9 99.8 — — — —Comp. Ex. 10 99.8 — — — — Comp. Ex. 11 99.4 — — — — Comp. Ex. 12 84 15 —— — Comp. Ex. 13 89 — 10 — — Comp. Ex. 14 84 — — 15 — Flame retarderSorts Content (wt %) Molecular weight of aromatic polymer Ex. 7 Inv. Sp.4 0.1 250000 Ex. 8 Inv. Sp. 5 0.1 120000 Ex. 9 Inv. Sp. 6 0.5 70000 Ex.10 Inv. Sp. 7 0.5 500000 Ex. 11 Inv. Sp. 8 0.05 31000 Ex. 12 Inv. Sp. 50.4 120000 Ex. 13 Inv. Sp. 4 0.5 250000 Ex. 14 Inv. Sp. 8 0.4 31000 Ex.15 Inv. Sp. 5 0.3 250000 Ex. 16 Inv. Sp. 9 0.3 50000 Comp. Ex. 9 Ctr.Sp. 4 0.1 9000 Comp. Ex. 10 Ctr. Sp. 5 0.1 20000 Comp. Ex. 11 Ctr. Sp. 90.5 18000 Comp. Ex. 12 Ctr. Sp. 7 0.4 9000 Comp. Ex. 13 Ctr. Sp. 4 0.520000 Comp. Ex. 14 Ctr. Sp. 5 0.4 18000 Flame retarders (IS) Anti-dripagents (wt %) (wt %) Combustibility test (UL94) Ex. 7 — 0.1 V-0prescription/passed Ex. 8 — 0.1 V-0 prescription/passed Ex. 9 — 0.1 V-0prescription/passed Ex. 10 — 0.1 V-0 prescription/passed Ex. 11 — 0.1V-0 prescription/passed Ex. 12 0.4 0.2 V-0 prescription/passed Ex. 130.3 0.2 V-0 prescription/passed Ex. 14 0.4 0.2 V-1 prescription/passedEx. 15 0.4 0.3 V-1 prescription/passed Ex. 16 0.4 0.3 V-0prescription/passed Comp. Ex. 9 — 0.1 V-1 prescription/not passed Comp.Ex. 10 — 0.1 V-1 prescription/not passed Comp. Ex. 11 — 0.1 V-1prescription/not passed Comp. Ex. 12 0.4 0.2 V-2 prescription/not passedComp. Ex. 13 0.3 0.2 V-2 prescription/not passed Comp. Ex. 14 0.4 0.2V-2 prescription/not passed

It is seen from the results of evaluation shown in Table 2 that theExamples 7 to 16, containing a flame retarder, composed of an aromaticpolymer, with a weight average molecular weight in a range from 31000 to500000, and sulfonic acid groups introduced therein, are superior inflame retardant properties to the Comparative Examples 9 to 14,containing a flame retarder, composed of an aromatic polymer, with aweight average molecular weight in a range from 9000 to 20000, andsulfonic acid groups introduced therein.

In the Comparative Examples, there were resins that were burned easilyand those that were not burned easily. The reason is that, in theComparative Examples, the flame retarder is not dispersed substantiallyevenly in the flame retardant resin composition, that is, thatcompatibility of the flame retarder in the resin to be rendered flameretardant is lowered.

Such is not the case with the Examples in which, by using a flameretarder composed of an aromatic polymer with a weight average molecularweight ranging between 31000 and 500000, and sulfonic acid groupsintroduced therein, the flame retarder is improved in compatibility withrespect to the resin to be rendered flame retardant, and hence the flameretarder is dispersed substantially evenly in the flame retardant resincomposition, so that proper flame retardant properties may be conferredon the resin to be made flame retardant.

It is also seen from the results of evaluation shown in Table 2 that,with the Examples, flame retardant properties may effectively beconferred by adding minor quantities of the flame retarder on the resinto be made flame retardant.

As may be seen from above, it is crucial, for producing a flameretardant resin composition, properly rendered flame retardant, that anaromatic polymer, with a weight average molecular weight in a rangebetween 31000 and 500000, into which sulfonic acid groups have beenintroduced, shall be contained as a flame retarder in the resin to berendered flame retardant.

Further embodiments of a flame retarder and a flame retardant resincomposition, employing this flame retarder, will now be described.

Similarly to the flame retardant resin composition of theabove-described embodiment, the flame retardant resin composition of thepresent embodiment is a resin material used e.g. for householdelectrical appliances, cars, office utensil, stationeries, groceries,building materials and fibers. Specifically, flame retardant propertiesare conferred on the resin composition, as the resin to be made flameretardant, by the flame retarder contained in the resin composition.

The flame retarder, contained in the flame retardant resin composition,is composed of an aromatic polymer, containing 1 mol % to 100 mol % ofmonomer units having an aromatic skeleton, and a preset quantity ofsulfonic acid groups and/or sulfonate groups introduced therein. Thearomatic skeleton may be present in a side chain or in a main chain ofthe aromatic polymer contained in the flame retarder.

Specifically, the aromatic polymer including the aromatic skeleton inits side chain may be enumerated by, for example, polystyrene (PS), highimpact polystyrene (HIPS: styrene-butadiene copolymer), anacrylonitrile-styrene copolymer (AS), an acrylonitrile-butadiene-styrenecopolymer (ABS), an acrylonitrile-chlorinated polyethylene resin (ACS),an acrylonitrile-styrene-acrylate copolymer (ASA), anacrylonitrile-ethylene propylene rubber-styrene copolymer (AES), and anacrylonitrile-ethylene-propylene-diene-styrene resin (AEPDMS). These maybe used either alone or in combination.

The weight average molecular weight of the aromatic polymer, having thearomatic skeleton in the side chain, is in a range from 10000 to10000000, preferably 50000 to 1000000 and more preferably 10000 to50000.

If, in the aromatic polymer, the weight average molecular weightdeviates from the range from 10000 to 10000000, it becomes difficult todisperse the flamer retarder substantially evenly in the resin to bemade flame retardant. That is, the flame retarder is lowered incompatibility with respect to the resin to be made flame retardant, suchthat flame retardant properties cannot be conferred adequately on theflame retardant resin composition.

The aromatic polymer, having an aromatic skeleton in its main chain, maybe enumerated by, for example, a polycarbonate (PC), polyphenylene oxide(PPO), polyethylene terephthalate (PET), polybutylene terephthalate(PBT), and polysulfone (PSF). These may be used either alone or incombination. The aromatic polymer, having an aromatic skeleton in itsmain chain, may also be used as a mixture (alloy) with e.g. otherresin(s). Specifically, the alloy with the other resin(s) may beenumerated by an ABS/PC alloy, a PS/PC alloy, an AS/PC alloy, a HIPS/PCalloy, a PET/PC alloy, a PBT/PC alloy, a PVC/PC alloy, a PLA(poly-lactic acid)/PC alloy, a PPO/PC alloy, a PS/PPO alloy, a HIPS/PPOalloy, an ABS/PET alloy and a PET/PBT alloy, which may be used eitheralone or in combination.

In the aromatic polymer, the content of the monomer units, havingaromatic skeletons, is in a range from 1 mol % to 100 mol %, preferablyin a range from 30 mol % to 100 mol % and more preferably in a rangefrom 40 mol % to 100 mol %.

If the content of the monomer units, having aromatic skeletons, is lessthan 1 mol %, the flame retarder becomes difficult to dispersesubstantially evenly in the resin, which should be made flame retardant,or the rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer becomes lower. Hence, flameretardant properties cannot be conferred appropriately on the flameretardant resin composition.

As the aromatic skeletons, forming the aromatic polymer, aromatichydrocarbons, aromatic esters, aromatic ethers (phenols), aromaticthioethers (thiophenols), aromatic amides, aromatic imides, aromaticamideimides, aromatic ether imides, aromatic sulfones and aromatic ethersulfones, having cyclic structures, such as benzene, naphthalene,anthracene, phenanthrene or coronene, are representative. Of thesearomatic skeletons, benzene rings or alkylbenzene ring structures aremost common.

The monomer units contained in the aromatic polymer, other than thearomatic skeleton, may be enumerated by, for example, acrylonitrile,butadiene, isoprene, pentadiene, cyclopentadiene, ethylene, propylene,butene, isobutylene, vinyl chloride, α-methylstyrene, vinyl toluene,vinyl naphthalene, acrylic acid, acrylates, methacrylic acid,methacrylates, maleic acid, fumaric acid and ethylene glycol, only byway of illustration. These may be used either alone or in combination.

As the aromatic polymer, used-up redeemed materials or scraps from theplant may be used. That is, low cost may be arrived at through use of aredeemed material as a feedstock material.

A flame retarder which, when contained in a preset amount in a resin tobe made flame retardant, may confer high flame retardant properties onthe resin, may be obtained by introducing preset amounts of sulfonicacid groups and/or sulfonates into the aromatic polymer. For introducingthe sulfonic acid groups and/or sulfonates into the aromatic polymer,such a method consisting in sulfonating an aromatic polymer with apreset amount of sulfonating agents may be used.

The sulfonating agent used for sulfonating an aromatic polymer ispreferably such a one containing less than 3 wt % of water.Specifically, the sulfonating agent is one or more selected from thegroup consisting of sulfuric anhydride, fuming sulfuric acid,chlorosulfonic acid and polyalkylbenzene sulfonic acid. As thesulfonating agent, complexes of, for example, alkyl phosphates ordioxane with Lewis bases may also be used.

If an aromatic polymer is sulfonated, with the use of 96 wt % sulfuricacid, as a sulfonating agent, to produce a flame retarder, cyano groupsin a polymer are hydrolyzed and converted into highly hygroscopic amideor carboxyl groups, so that a flame retarder containing these amide orcarboxyl groups is produced. If the flame retarder, containing theseamide or carboxyl groups in larger quantities, is used, the moisture istaken up from outside with lapse of time, so that the flame retardantresin composition is changed in color to detract from appearance, or theresin is deteriorated in mechanical strength, even granting that highflame retardant properties may be imparted to the flame retardant resincomposition. A specified example of this sort of the flame retarder isthe sulfonate flame retarder proposed in, for example, the JP Laid-OpenPatent Publication 2001-2941.

In light of the above, sulfonation of an aromatic polymer may beaccomplished by a method consisting in adding a preset amount of apreset sulfonating agent into a solution obtained on dissolving anaromatic polymer in an organic solvent (chlorine based solvent). Thereis also such a method consisting in adding a preset amount of thesulfonating agent to a liquid obtained on dispersing a pulverulentacrylonitrile-styrene based polymer in an organic solvent (liquid whichis not a solution) to carry out reaction. There are also such a methodconsisting in directly injecting an aromatic polymer into a sulfonatingagent, and such a method consisting in directly spraying a sulfonatinggas, specifically a gas of a sulfuric anhydride (SO₃), to a pulverulentacrylonitrile-styrene based polymer, to carry out reaction. Of thesemethods, the method consisting in directly spraying a sulfonating gasinto a pulverulent aromatic polymer without employing an organic solventis more preferred.

To the aromatic polymer are introduced the sulfonic acid groups (—SO₃H)or the sulfonate groups either directly or as these groups have beenneutralized with ammonia or amine compounds. Specifically, the sulfonategroups may be enumerated by, for example, Specified examples of thesulfonate groups include Na, K, Li, Ca, Mg, Al, Zn, Sb and Sn saltgroups of sulfonic acid.

It is noted that higher flame retardant properties may be conferred onthe flame retardant resin composition when sulfonate groups, rather thanthe sulfonic acid groups, have been introduced into the aromaticpolymer. Of these, Na salts, Ka salts and Ca salts of sulfonic acid arepreferred.

The rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer may be adjusted by the amount ofaddition of the sulfonating agent, the time of reaction of thesulfonating agent, reaction temperature or the kind as well as theamount of the Lewis base. Of these, the amount of addition of thesulfonating agent, the time of reaction of the sulfonating agent and thereaction temperature are most preferred to use for adjustment.

Specifically, the rate of the sulfonic acid groups and/or the sulfonategroups introduced into the aromatic polymer is 0.01 mol % to 14.9 wt %,preferably 0.05 mol % to 12 mol % and more preferably 1 mol % to 10 mol%.

In case the rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer is lower than 0.01 mol %, itbecomes difficult to confer flame retardant properties to the flameretardant resin composition. If conversely the rate of the sulfonic acidgroups and/or the sulfonate groups introduced into the aromatic polymeras sulfur contents is more than 14.9 mol %, the flame retardant resincomposition tends to be lowered in compatibility with respect to theresin composition, or the flame retardant resin composition tends to bedeteriorated in mechanical strength with lapse of time.

The rate of the sulfonic acid groups and/or the sulfonate groupsintroduced into the aromatic polymer may readily be determined byquantitative analysis, by e.g. a combustion flask method, of the sulfur(S) contents in the sulfonated aromatic polymer, as an example. If therate of the sulfonic acid groups and/or the sulfonate groups introducedinto the aromatic polymer is determined on the basis of sulfur contentin the aromatic polymer, the sulfur content in the aromatic polymer isnormally in a range from 0.001 wt % to 4.1 wt % and preferably in arange from 0.005 wt % to 2.5 wt %, depending on for example the sort ofthe aromatic polymer.

The resin which is to be rendered flame retardant, as a feedstockmaterial for the resin composition on which flame retardant propertiesare to be conferred by the above-described flame retarder, containedtherein, that is, the flame retardant resin composition, may beenumerated by, for example, polycarbonate (PC), anacrylonitrile-butadiene-styrene copolymer (ABS), polystyrene (PS), anacrylonitrile-styrene copolymer (AS), polyvinyl chloride (PVC),polyphenylene oxide (PPO), polyethylene terephthalate (PET),polyethylene butylate (PBT), polysulfone (PSF), thermoplastic elastomer(TPE), polybutadiene (PB), polyisoprene (PI), nitrile rubber(acrylonitrile-butadiene rubber), nylon and poly-lactic acid (PLA). Theresin composition contains one or more of these resins in an amount notless than 5 wt %. These may be used either alone or in combination (asalloys).

The resins to be most effectively rendered flame retardant by containingthe aforementioned flame retarder may be enumerated by, for example, PC,ABS, (HI)PS, AS, PPO, PBT, PET, PVC, PLA, ABS/PC alloy, PS/PC alloy,AS/PC alloy, HIPS/PC alloy, PET/PC alloy, PBT/PC alloy, PVC/PC alloy,PLA (poly-lactic acid)/PC alloy, PPO/PC alloy, PS/PPO alloy, HIPS/PPOalloy, ABS/PET alloy and PET/PBT alloy. These may be used either aloneor in combination.

By using a flame retarder composed of the aromatic polymer, into whichhave been introduced sulfonic acid groups or sulfonate groups in anamount in a range from 0.01 mol % to 14.9 mol %, it is possible toincrease the number of the sorts of the resins to be rendered flameresistant.

As the resins to be rendered flame retardant, used-up redeemed materialsor scraps from the plant may be used. That is, low cost may be arrivedat through use of a redeemed material as a feedstock material.

In the above-described flame retardant resin composition, in which aflame retarder used is an aromatic polymer, into which have beenintroduced sulfonic acid groups or sulfonate groups in an amount in arange from 0.01 mol % to 14.9 mol %, the flame retarder may be improvedin compatibility with respect to the resin to be rendered flameresistant, so that flame retardant properties may properly be conferredon the resin.

Moreover, in the above-described flame retardant resin composition, theflame retarder contained may be obtained by sulfonating the aromaticpolymer with the sulfonating agent, containing less than 3 wt % ofwater, so that the amide or carboxyl groups, exhibiting high hygroscopiceffects, may be suppressed from being introduced into the flameretarder. Consequently, there is no fear of the resin taking up themoisture in atmospheric air during prolonged storage and becomingdiscolored to detract from appearance or deteriorated in mechanicalstrength.

Furthermore, in the flame retardant resin composition, the content ofthe flame retarder in the resin to be made flame retardant is in a rangefrom 0.001 wt % to 10 wt %, preferably in a range from 0.005 wt % to 5wt % and more preferably in a range from 0.01 wt % to 3 wt %.

In case the content of the flame retarder in the resin to be renderedflame retardant is less than 0.001 wt %, it becomes difficult to conferflame retardant properties effectively on the flame retardant resincomposition. If conversely the content of the flame retarder in theresin to be rendered flame retardant exceeds 10 wt %, the reverse effectis presented, that is, the flame retardant resin composition is moresusceptible to combustion.

That is, the flame retardant resin composition, on which the flameretardant properties have been conferred effectively, may be obtained byadding a minor quantity of the flame retarder to the resin.

The above-described flame retardant resin composition may also be addedby known routine flame retarders, in addition to the above-describedflame retarders, for further improving the flame retardant properties.

These known routine flame retarders may be enumerated by, for example,organic phosphate based flame retarders, halogenated phosphate basedflame retarders, inorganic phosphorus based flame retarders, halogenatedbisphenol based flame retarders, halogen compound based flame retarders,antimony based flame retarders, nitrogen based flame retarders, boronbased flame retarders, metal salt based flame retarders, inorganic flameretarders and silicon based flame retarders. These may be used eithersingly or in combination.

Specifically, the organic phosphate or phosphite based flame retardersmay be enumerated by, for example, triphenyl phosphate, methyl neobenzylphosphate, pentaerythrytol diethyl diphosphate, methyl neopentylphosphate, phenyl neopentyl phosphate, pentaerythrytol diphenyldiphosphate, dicyclopentyl hypodiphosphate, dineopentyl hypodiphosphite,phenyl pyrocatechol phosphite, ethyl pyrocatechol phosphate anddipyrocatechol hypodiphosphate. These may be used either alone or incombination.

The halogenated phosphate based flame retarders may be enumerated by,for example, tris(β-chloroethyl)phosphate, tris(dicyclopropyl)phosphate,tris(β-bromoethyl)phosphate, tris(dibromopropyl)phosphate,tris(chloropropyl)phosphate, tris(dibromophenyl)phosphate,tris(tribromophenyl)phosphate, tris(tribromoneopentyl)phosphate,condensed polyphosphates and condensed polyphosphonates. These may beused either alone or in combination.

The inorganic phosphorus based flame retarder may be exemplified by, forexample, red phosphorus and inorganic phosphates. These may be usedeither alone or in combination.

The halogenated bisphenol based flame retarder may be enumerated by, forexample, tetrabromobisphenol A, oligomers thereof andbis(bromoethylether)tetrabromobisphenol A. These may be used eitheralone or in combination.

The halogen compound based flame retarder may be enumerated bydecabromodiphenyl ether, hexabromobenzene, hexabromocyclododecane,tetrabromo phthalic anhydride, (tetrabromobisphenol)epoxy oligomer,hexabromobiphenyl ether, tribromophenol, dibromocresyl glycidyl ether,decabromodiphenyl oxide, halogenated polycarbonates, halogenatedpolycarbonate copolymers, halogenated polystyrene, halogenatedpolyolefins, chlorinated paraffins and perchlorocyclodecane. These maybe used either alone or in combination.

The antimony based flame retarders may be enumerated by, for example,antimony trioxide, antimony tetroxide, antimony pentoxide and sodiumantimonate. These may be used either alone or in combination.

The nitrogen-based flame retarders may be enumerated by, for example,melamine, alkyl group or aromatic group substituted melamine, melaminecyanurate, melamine isocyanurate, melamine phosphate, triazine,guanidine compounds, urea, various cyanuric acid derivatives, andphosphasene compounds. These may be used either alone or in combination.

The boron based flame retarders may be enumerated by, for example, zincborate, zinc metaborate and barium metaborate. These may be used eitheralone or in combination.

The metal salt based flame retarders may be enumerated by, for example,alkyl metal salts or alkyl earth metal salts of perfluoroalkane sulfonicacids, alkylbenzene sulfonic acids, halogenated alkylbenzene sulfonicacids, alkylsulfonic acids and naphthalene sulfonic acid. These may beused either alone or in combination.

The inorganic flame retarders may be enumerated by, for example,magnesium hydroxide, aluminum hydroxide, barium hydroxide, calciumhydroxide, dolomite, hydrotalcite, basic magnesium carbonate, zirconiumhydroxide, hydrates of inorganic metal compounds, such as hydrates oftin oxide, metal oxides, such as aluminum oxide, iron oxide, titaniumoxide, manganese oxide, magnesium oxide, zirconium oxide, zinc oxide,molybdenum oxide, cobalt oxide, bismuth oxide, chromium oxide, tinoxide, nickel oxide, copper oxide and tungsten oxide, powders of metals,such as aluminum, iron, copper, nickel, titanium, manganese, tin, zinc,molybdenum, cobalt, bismuth, chromium, tungsten and antimony, andcarbonates, such as zinc carbonates, magnesium carbonate, calciumcarbonate and barium carbonate. These may be used either alone or incombination.

Of the inorganic flame retarders, magnesium hydroxide, aluminumhydroxide, talc, which is a hydrated magnesium silicate, basic magnesiumcarbonate, mica, hydrotalcite, and aluminum are preferred from theperspective of flame retardant properties and from economicprofitability. Meanwhile, used-up redeemed materials or scraps from theplant may be used as the inorganic flame retarders.

The silicon-based flame retarders may be exemplified by, for example,polyorganosiloxane resins (silicone or organic silicates) and silica,which may be used either alone or as a mixture. The polyorganosiloxaneresins may be enumerated by, for example, polymethylethyl siloxaneresin, polydimethyl siloxane resin, polymethyl phenyl siloxane resin,polydiphenyl siloxane resin, polydiethyl siloxane resin, polyethylphenyl siloxane resin and mixtures thereof.

The alkyl moiety portions of these polyorganosiloxane resins may containfunctional groups, for example, an alkyl group, an alkoxy group, ahydroxy group, an amino group, a carboxyl group, a silanol group, amercapto group, an epoxy group, a vinyl group, an aryloxy group, apolyoxyalkylene group, a hydroxy group or halogens. Of these, the alkylgroup, an alkoxy group and the vinyl group are most preferred.

The polyorganosiloxane resins are of the average molecular weight notless than 100, preferably in a range from 500 to 5000000, and are in theform of oil, varnish, gum, powders or pellets. As for silica, it isdesirably surface-processed with a silane coupling agent of ahydrocarbon compound.

The content of the known common flame retarders, given hereinabove, isusually in a range from 0.001 wt % to 50 wt %, preferably in a rangefrom 0.01 wt % to 30 wt % and more preferably in a range from 0.1 wt %to 10 wt %, referred to the resin to be rendered flame retardant,depending on the sort of the flame retarder, level of flame retardantproperties or on the sort of the resin to be rendered flame retardant.

In the flame retardant resin composition, known routine inorganicfillers may be mixed, in addition to the above-mentioned flameretarders, for improving mechanical strength or for further improvingflame retardant properties.

Among the known inorganic fillers, there are, for example, crystallinesilica, fused silica, alumina, magnesia, talc, mica, kaolin, clay,diatomaceous earth, calcium silicate, titanium silicate, titanium oxide,glass fibers, calcium fluoride, calcium sulfate, barium sulfate, calciumphosphate, carbon fibers, carbon nanotubes and potassium titanatefibers. These may be used either alone or as a mixture. Of theseinorganic fillers, talc, mica, carbon, glass and carbon nanotubes aremost preferred.

The inorganic fillers are contained in the flame retardant resincomposition in an amount in a range from 0.1 wt % to 90 wt %, preferablyin a range from 0.5 wt % to 50 wt % and more preferably in a range from1 wt % to 30 wt %.

If the content of the inorganic filler is less than 0.1 wt %, the effectof improving the toughness or the flame retardant properties of theflame retardant resin composition is lowered. If conversely the contentof the inorganic filler is higher than 90 wt %, such undesirablesituation may arise that, in injection molding the flame retardant resincomposition, the flame retardant resin composition in a molten state islowered in fluidity or in mechanical strength.

Furthermore, in the flame retardant resin composition, fluoro olefinresins, for example, may be mixed, in addition to the above-mentionedflame retarders, for suppressing the dripping phenomenon that mayotherwise occur during the combustion.

Among the fluoro olefin resins, capable of suppressing the drippingphenomenon, there are, for example, a difluoroethylene polymer, atetrafluoroethylene polymer, a tetrafluoroethylene-hexafluoropropylenecopolymer and a copolymer of a tetrafluoroethylene and an ethylenicmonomer. These may be used either alone or in combination.

Of these fluoro olefin resins, tetrafluoroethylene polymers are mostpreferred. The average molecular weight of the tetrafluoroethylenepolymers is not less than 50000 and preferably in a range from 100000 to20000000. Meanwhile, the fluoro olefin resins, exhibiting fibril formingproperties, are more preferred.

The fluoro olefin resins are contained in a range from 0.001 wt % to 5wt %, preferably in a range from 0.005 wt % to 2 wt % and morepreferably in a range from 0.01 wt % to 0.5 wt %, referred to the flameretardant resin composition.

If the content of the fluoro olefin resins is less than 0.001 wt %, itbecomes difficult to suppress the dripping phenomenon. If conversely thecontent of the fluoro olefin resins is more than 5 wt %, the effect insuppressing the dripping phenomenon becomes saturated, so that there mayarise inconveniences such as high cost or the inferior mechanicalstrength.

In the flame retardant resin composition, there may be added, inaddition to the above-mentioned flame retardants, anti-oxidants(phenolic, phosphorus based or sulfur based anti-oxidants), anti-staticagents, UW absorbers, photo-stabilizers, plasticizers, compatibilitypromoting agents, colorants (pigments or dyestuffs), bactericidalagents, hydrolysis inhibiting agents or surface processing agents forimproving injection molding properties, shock-proofing properties,appearance, thermal resistance, weatherability or toughness.

In preparing the above-mentioned flame retardant resin composition, aflame retarder, a resin to be rendered flame retardant, and otheradditives, are dispersed substantially evenly in a kneader, such as atumbler, a reblender, a mixer, an extruder or a co-kneader. Theresulting product is molded to a preset shape by molding methods, suchas injection molding, injection compression molding, extrusion molding,blow molding, vacuum molding, press molding, foam molding orsupercritical molding.

The molded product, formed of the flame retardant resin composition, isused in various fields as enclosures or component parts of variousproducts exhibiting flame retardant properties, such as householdelectrical appliances, cars, information equipment, office utensils,telephone sets, stationeries, furniture or fibers.

The present invention will now be described with reference to Examplesand Comparative Examples for comparison to the Examples.

First, inventive samples and control samples of flame retarders,contained in the Examples and Comparative Examples, were prepared.

(Inventive Sample 10)

In preparing an inventive sample 10, 2.6 g of a styrene homopolymer(weight average molecular weight: 280000), as an aromatic polymer, werecharged in a round-bottomed flask, into which were previously charged23.4 g of 1,2-dichloroethane, for dissolution, to form a polymersolution. A liquid mixture of 0.25 g of 96% sulfuric acid and 0.3 g ofsulfuric anhydride was charged dropwise into the polymer solution overten minutes. After the end of the dripping, the resulting mass was curedfor four hours, by way of sulfonating the aromatic polymer. The reactionliquid was poured into boiling pure water to remove the solvent to yielda solid substance. This solid substance was rinsed thrice with lukewarmpure water and dried under reduced pressure to yield a dried solidsubstance.

The flame retarder, thus prepared, was subjected to elementary analysis,using a combustion flask method. From the sulfur content in the soproduced flame retarder, the rate of the sulfonic acid groups introducedwas found to be 8 mol %.

The dried solid substance was neutralized with potassium hydroxide andagain dried to prepare a flame retarder. In this manner, an aromaticpolymer, containing the sulfonic acid groups introduced therein, wasobtained as a flame retarder.

(Inventive Sample 11)

In preparing an inventive sample 11, a blade of a used-up fan wascrushed, as an aromatic polymer. 3 g of an acrylonitrile-styrenecopolymer resin (acrylonitrile unit: 44 mol %; styrene unit: 56 mol %)of a 83 mesh pass size, thus obtained, was charged into a round-bottomedflask, and agitated. As the resin powders were continuously stirred, anSO₃ gas, evolved from 4 g of fuming sulfuric acid, was blown over fourhours into the powdered material, which was continuously stirred, by wayof sulfonating the aromatic polymer. Air was then sent into the flask toremove residual SO₃ gas from the round-bottomed flask. The solidsubstance was washed thrice with water and subsequently dried.

The solid substance, thus prepared, was put to elementary analysis,using a combustion flask method. The introducing rate of sulfonic acidgroups was found to be 7.2 mol %.

The dried solid substance was then neutralized with potassium hydroxideand again dried to yield a flame retarder in the form of a pale yellowsolid substance. That is, the inventive sample 11 is again an aromaticpolymer into which sulfonic acid groups have been introduced.

(Inventive Sample 12)

In an inventive sample 12, a flame retarder was obtained in the same wayas in the above inventive sample 11, except using, as an aromaticpolymer, an acrylonitrile-butadiene-styrene copolymer resin(acrylonitrile unit: 38 mol %; styrene unit: 50 mol %; butadiene unit:12 mol %; color: black color), obtained on crushing a used-up 8 mmcassette to a 83 mesh pass size, and setting the time for sulfonatingprocessing to ten minutes. That is, the inventive sample 12 is again anaromatic polymer, into which were introduced sulfonic acid groups.Similarly to the aforementioned inventive sample 12, the solidsubstance, prepared as described above, was put to elementary analysis,using a combustion flask method. The introducing rate of sulfonic acidgroups was found to be 0.10 mol %.

(Inventive Sample 13)

In an inventive sample 13, a flame retarder in the form of a white solidsubstance was prepared in the same way as in inventive sample 11, exceptemploying polyethylene terephthalate as an aromatic polymer. That is,the inventive sample 13 is again an aromatic polymer, into which wereintroduced sulfonic acid groups. The solid substance, thus prepared, wasput to elementary analysis, in the same way as the inventive sample 10,using a combustion flask method. The introducing rate of sulfonic acidgroups was found to be 0.12 mol %.

(Inventive Sample 14)

In an inventive sample 14, a flame retarder in the form of a white solidsubstance was prepared in the same way as in inventive sample 11, exceptemploying powdered polycarbonate, obtained on crushing a transparentoptical disc from the plant to 83 mesh pass size, as an aromaticpolymer. That is, the inventive sample 14 is again an aromatic polymer,into which were introduced sulfonic acid groups. The solid substance,thus prepared, was put to elementary analysis, in the same way as theinventive sample 10, using a combustion flask method. The introducingrate of sulfonic acid groups was found to be 2 mol %.

(Inventive Sample 15)

In an inventive sample 15, a flame retarder in the form of a brown solidsubstance was prepared in the same way as in inventive sample 11, exceptemploying powdered poly(2,6-dimethyl-p-phenylene oxide) as the aromaticpolymer. That is, the inventive sample 15 was again an aromatic polymer,into which were introduced sulfonic acid groups. The solid substance,thus prepared, was put to elementary analysis, in the same way as theinventive sample 10, using a combustion flask method. The introducingrate of sulfonic acid groups was found to be 7.5 mol %.

(Control Sample 7)

In preparing a control sample 7, 2 g of a styrene homopolymer, used inthe inventive sample 10, as an aromatic polymer, was charged in around-bottomed flask, into which were previously charged 18 g of1,2-dichloroethane, for dissolution, to form a polymer solution. Aliquid mixture of 15 g of 1,2-dichloroethane, 0.6 g of triethylphosphate and 2.3 g of fuming sulfuric acid was charged dropwise intothe polymer solution over 1.5 hours. After the end of the dripping, theresulting mass was cured for two hours, by way of sulfonating thearomatic polymer. A deposited product was taken out, dissolved inmethanol and re-precipitated in diethylether. The resulting precipitatewas dried to yield a solid substance.

The solid substance, thus prepared, was subjected to elementaryanalysis, using a combustion flask method. The introducing rate of thesulfonic acid groups was found to be 65 mol %.

The dried solid substance was neutralized with potassium hydroxide andagain dried to prepare a flame retarder. In this manner, an aromaticpolymer, containing 65 mol % of the sulfonic acid groups, introducedtherein, was obtained as a flame retarder.

(Control Sample 8)

In a control sample 8, sodium polystyrenesulfonate (weight averagemolecular weight: 18000) was used as a flame retarder. This flameretarder was subjected to elementary analysis, using a combustion flaskmethod. The introducing rate of the sulfonic acid groups was found to be99 mol %.

(Control Sample 9)

In the control sample 9, a flame retarder, formed of a black solidsubstance, was prepared in the same way as in the inventive sample 12,except employing 90 wt % of concentrated sulfuric acid, as a sulfonatingagent used for sulfonating processing, and carrying out the sulfonatingprocessing in an 80° C. atmosphere for one hour. The flame retarder,thus prepared, was put to elementary analysis by a combustion flaskmethod, in the same way as the inventive sample 10. The introducing rateof sulfonic acid groups was 36 mol %. An aromatic polymer, containing 36mol % of sulfonic acid groups, introduced therein, was prepared.

The inventive samples 10 to 15 and the control samples 7 to 9, that is,flame retarder samples, were introduced into a preset resin, which is tobe made flame retardant, in order to prepare Examples and ComparativeExamples.

EXAMPLE 17

In Example 17, 99.8 parts by weight of a polycarbonate resin (bisphenolA type), referred to below as PC, as a resin to be made flame retardant,0.1 part by weight of the inventive sample 10, as a flame retarder, and0.1 part by weight of fibril-forming polytetrafluoroethylene, referredto below as PTFE, as an anti-drip agent, were mixed together to preparea flame retardant resin precursor. This flame retardant resin precursorwas charged into an extruder and formed into pellets by kneading at apreset temperature. The pellets, thus formed, were charged into aninjection molding apparatus, for injection molding at a presettemperature, in order to prepare a strip-shaped test piece, 1.5 mm inthickness, formed of the flame retardant resin composition.

EXAMPLE 18

In Example 18, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 99.85 parts by weight of PC, as a resin tobe made flame retardant, 0.05 part by weight of the inventive sample 11,as a flame retarder, and 0.1 part by weight of PTFE, as an anti-dripagent, in order to prepare a flame retardant resin precursor.

EXAMPLE 19

In Example 19, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 99.85 parts by weight of PC, as a resin tobe made flame retardant, 0.05 part by weight of the inventive sample 14,as a flame retarder, and 0.1 part by weight of PTFE, as an anti-dripagent, in order to prepare a flame retardant resin precursor.

EXAMPLE 20

In Example 20, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 83.8 parts by weight of PC, as a resin tobe made flame retardant and 15 parts by weight of anacrylonitrile-butadiene-styrene copolymer resin, with a weight ratioacrylonitrile/polybutadiene/styrene=24/20/56, referred to below as ABSresin, as another resin to be made flame retardant, 0.5 part by weightof the inventive sample 12, as a flame retarder, 0.5 part by weight ofpolymethyl phenyl siloxane, referred to below as SI, as a silicon-basedflame retarder, used as another flame retarder, and 0.2 part by weightof PTFE, as an anti-drip agent, to prepare a flame retardant resinprecursor.

EXAMPLE 21

In Example 21, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 89.5 parts by weight of PC, as a resin tobe made flame retardant, 10 parts by weight of rubber-modifiedpolyethylene, with a polybutadiene/polystyrene weight ratio of 10:90,referred to below as HIPS resin, as another resin to be made flameretardant, 0.1 part by weight of the inventive sample 11, as a flameretarder, 0.2 part by weight of SI, as another flame retarder, and 0.2part by weight of PTFE, as an anti-drip agent, in order to prepare aflame retardant resin precursor.

EXAMPLE 22

In Example 22, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 89.4 parts by weight of PC, as a resin tobe made flame retardant, 10 parts by weight of an acrylonitrile-styrenecopolymer resin, with a weight ratio of acrylonitrile/styrene=25/75,referred to below as AS resin, as another resin to be made flameretardant, 0.2 part by weight of the inventive sample 10, as a flameretarder, 0.2 part by weight of SI, as another flame retarder, and 0.2part by weight of PTFE, as an anti-drip agent, to prepare a flameretardant resin precursor.

EXAMPLE 23

In Example 23, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 84 parts by weight of PC, as a resin to bemade flame retardant, 15 parts by weight of polyethylene terephthalate,referred to below as PET, as another resin to be made flame retardant,0.3 part by weight of the inventive sample 13, 0.4 part by weight of SI,as another flame retarder, and 0.3 part by weight of PTFE, as ananti-drip agent, in order to prepare a flame retardant resin precursor.

EXAMPLE 24

In Example 24, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 49 parts by weight of PC, as a resin to bemade flame retardant, 50 parts by weight of poly-lactic acid, referredto below as PLA, as another resin to be made flame retardant, 0.2 partby weight of the control sample 14, as a flame retarder, 0.5 part byweight of SI, as another flame retarder, and 0.3 part by weight of PTFE,as an anti-drip agent, in order to prepare a flame retardant resinprecursor.

EXAMPLE 25

In Example 25, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 99 parts by weight of ABS as a resin to bemade flame retardant, 0.5 part by weight of the control sample 11, as aflame retarder, 0.2 part by weight of SI, as another resin to be madeflame retardant, 0.2 part by weight of SI, as another flame retarder,and 0.3 part by weight of PTFE, as an anti-drip agent, in order toprepare a flame retardant resin precursor.

EXAMPLE 26

In Example 25, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 99 parts by weight of PET as a resin to bemade flame retardant, 0.5 part by weight of the control sample 13, as aflame retarder, 0.2 part by weight of SI, as another flame retarder, and0.3 part by weight of PTFE, as an anti-drip agent, in order to prepare aflame retardant resin precursor.

EXAMPLE 27

In Example 27, a strip-shaped test piece was formed in the same way asin Example 17, except mixing 99.8 parts by weight of PC as a resin to bemade flame retardant, 0.1 part by weight of the control sample 15, as aflame retarder, and 0.1 part by weight of PTFE, as an anti-drip agent,in order to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 15

In Comparative Example 15, a strip-shaped test piece was formed in thesame way as in Example 17, except mixing 99.8 parts by weight of PC as aresin to be made flame retardant, 0.1 part by weight of the controlsample 7, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, in order to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 16

In Control Example 16, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 99.8 parts by weight of PC as aresin to be made flame retardant, 0.1 part by weight of the controlsample 8, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 17

In Control Example 17, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 99.85 parts by weight of PC as aresin to be made flame retardant, 0.05 part by weight of the controlsample 9, as a flame retarder, and 0.1 part by weight of PTFE, as ananti-drip agent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 18

In Control Example 18, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 83.8 parts by weight of PC as aresin to be made flame retardant, 15 parts by weight of an ABS resin, asanother resin to be made flame retardant, 0.5 part by weight of thecontrol sample 9, as a flame retarder, 0.5 part by weight of SI, asanother flame retarder, and 0.2 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 19

In Control Example 19, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 89.5 parts by weight of PC as aresin to be made flame retardant, 10 parts by weight of an HIPS resin,as another resin to be made flame retardant, 0.1 part by weight of thecontrol sample 7, as a flame retarder, 0.2 part by weight of SI, asanother flame retarder, and 0.2 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 20

In Control Example 20, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 89.4 parts by weight of PC as aresin to be made flame retardant, 10 parts by weight of an AS resin, asanother resin to be made flame retardant, 0.2 part by weight of thecontrol sample 8, as a flame retarder, 0.2 part by weight of SI, asanother flame retarder, and 0.2 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 21

In Control Example 21, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 84 parts by weight of PC as a resinto be made flame retardant, 15 parts by weight of a PET resin, asanother resin to be made flame retardant, 0.3 part by weight of thecontrol sample 9, as a flame retarder, 0.4 part by weight of SI, asanother flame retarder, and 0.3 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 22

In Control Example 22, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 49 parts by weight of PC as a resinto be made flame retardant, 50 parts by weight of a PLA resin, asanother resin to be made flame retardant, 0.2 part by weight of thecontrol sample 7, as a flame retarder, 0.5 part by weight of SI, asanother flame retarder, and 0.3 part by weight of PTFE, as an anti-dripagent, to prepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 23

In Control Example 23, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 99 parts by weight of ABS as a resinto be made flame retardant, 0.5 part by weight of the control sample 8,as a flame retarder, 0.2 part by weight of SI, as another flameretarder, and 0.3 part by weight of PTFE, as an anti-drip agent, toprepare a flame retardant resin precursor.

COMPARATIVE EXAMPLE 24

In Control Example 24, a strip-shaped test piece was formed in the sameway as in Example 17, except mixing 99 parts by weight of PET as a resinto be made flame retardant, 0.5 part by weight of the control sample 9,as a flame retarder, 0.2 part by weight of SI, as another flameretarder, and 0.3 part by weight of PTFE, as an anti-drip agent, toprepare a flame retardant resin precursor.

The test on combustibility and the test on appearance were then carriedout on the respective Examples and Comparative Examples.

The tests on combustibility were conducted as perpendicularcombustibility tests in accordance with V-0, V-1 and V-2 prescriptionsof UL 94 (Underwriters' Laboratory Subject 94). Specifically, five testpieces each of the Examples and the Comparative Examples were provided,and a burner flame was applied to each of the strip-shaped test piecessupported substantially upright. This state was maintained for tenseconds and thereafter the burner flame was separated from the testpieces. When the flame was extinguished, the burner flame was appliedfor further ten seconds, after which the burner flame was separated fromthe test pieces. Decision was given at this time on the basis of the sumof the time duration of combustion with flame after the end of the firstflame contact with the test pieces, the time duration of combustion withflame after the end of the second flame contact with the test pieces,the time duration of combustion with flame after the end of the secondflame contact with the test pieces, and the time duration of combustionwithout flame after the end of the second flame contact with the testpieces, the sum of time durations of combustion with flame of the fivetest pieces, and the presence/absence of the droppings of combustion.The V-0 prescription provides that combustion with flame shall come to aclose within ten seconds for the first and second combustion events. TheV-1 and V-2 prescriptions provide that combustion with flame shall cometo a close within 30 seconds for the first and second combustion events.The sum of the time durations of the second combustion with flame andthose without flame is less than 30 seconds for the V-0 prescription andwithin 60 seconds for the V-1 and V-2 prescriptions. The sum of the timedurations of combustion with flame of the five test pieces is within 50seconds for the V-0 prescription and within 250 seconds for the V-1 andV-2 prescriptions. The droppings of combustion are tolerated only forthe V-2 prescription. That is, with the UL combustion test method (UL94), the flame retardant properties become higher in the order of theV-0, V-1 and V-2.

Turning to the test on the appearance, the test pieces of the Examplesand the Comparative Examples were exposed for 30 days in a constanttemperature constant pressure vessel of 80° C. atmosphere and 80%relative humidity, and the appearance of the test pieces were checkedvisually. The case without changes in color was indicated with ∘ and thecase with changes in color was indicated with x.

The results of evaluation of the combustibility test and the appearancetest of the Examples and the Comparative Examples are shown in thefollowing Table 1.

TABLE 3 Resins to be made flame resistant (wt %) PC ABS HIPS AS PET PLAEx. 17 99.8 — — — — — Ex. 18 99.85 — — — — — Ex. 19 99.85 — — — — — Ex.20 83.8 15.0 — — — — Ex. 21 89.5 — 10.0 — — — Ex. 22 89.4 — — 10.0 — —Ex. 23 84.0 — — — 15.0 — Ex. 24 49.0 — — — — 50.0 Ex. 25 — 99.0 — — — —Ex. 26 — — — — 99.0 — Ex. 27 99.8 — — — — — Comp. Ex. 15 99.8 — — — — —Comp. Ex. 16 99.8 — — — — — Comp. Ex. 17 99.85 — — — — — Comp. Ex. 1883.8 15.0 — — — — Comp. Ex. 19 89.5 — 10.0 — — — Comp. Ex. 20 89.4 — —10.0 — — Comp. Ex. 21 84.0 — — — 15.0 — Comp. Ex. 22 49.0 — — — — 50.0Comp. Ex. 23 — 99.0 — — — — Comp. Ex. 24 — — — — 99.0 — Flame retardersIntroducing rate of sulfonic acid sorts groups (mol %) Content (wt %)Ex. 17 Inv. Sp. 10 8.0 0.1 Ex. 18 Inv. Sp. 11 7.2 0.05 Ex. 19 Inv. Sp.14 0.1 0.05 Ex. 20 Inv. Sp. 12 0.12 0.5 Ex. 21 Inv. Sp. 11 2.0 0.1 Ex.22 Inv. Sp. 10 7.5 0.2 Ex. 23 Inv. Sp. 13 0.3 Ex. 24 Inv. Sp. 14 0.2 Ex.25 Inv. Sp. 11 0.5 Ex. 26 Inv. Sp. 13 0.5 Ex. 27 Inv. Sp. 15 0.1 Comp.Ex. 15 Comp. Sp. 17 65 0.1 Comp. Ex. 16 Comp. Sp. 18 99 0.1 Comp. Ex. 17Comp. Sp. 19 36 0.05 Comp. Ex. 18 Comp. Sp. 9 0.5 Comp. Ex. 19 Comp. Sp.7 0.1 Comp. Ex. 20 Comp. Sp. 8 0.2 Comp. Ex. 21 Comp. Sp. 9 0.3 Comp.Ex. 22 Comp. Sp. 7 0.2 Comp. Ex. 23 Comp. Sp. 8 0.5 Comp. Ex. 24 Comp.Sp. 9 0.5 Inspection on appearance following high CombustibilityAnti-drip temperature (IS) (wt %) agent (wt %) Combustibility test(UL94) storage Ex. 17 — 0.1 V-0 prescription passed ∘ Ex. 18 — 0.1 V-0prescription passed ∘ Ex. 19 — 0.1 V-0 prescription passed ∘ Ex. 20 0.50.2 V-0 prescription passed ∘ Ex. 21 0.2 0.2 V-0 prescription passed ∘Ex. 22 0.2 0.2 V-0 prescription passed ∘ Ex. 23 0.4 0.3 V-0 prescriptionpassed ∘ Ex. 24 0.5 0.3 V-1 prescription passed ∘ Ex. 25 0.2 0.3 V-2prescription passed ∘ Ex. 26 0.2 0.3 V-2 prescription passed ∘ Ex. 27 —0.1 V-0 prescription passed ∘ Comp. Ex. 15 — 0.1 V-0 prescription notpassed ∘ Comp. Ex. 16 — 0.1 V-1 prescription not passed ∘ Comp. Ex. 17 —0.1 V-1 prescription not passed x Comp. Ex. 18 0.5 0.2 V-1 prescriptionnot passed x Comp. Ex. 19 0.2 0.2 V-0 prescription not passed ∘ Comp.Ex. 20 0.2 0.2 V-2 prescription not passed ∘ Comp. Ex. 21 0.4 0.3 V-1prescription not passed x Comp. Ex. 22 0.5 0.3 V-1 prescription notpassed ∘ Comp. Ex. 23 0.2 0.3 V-2 prescription not passed ∘ Comp. Ex. 240.2 0.3 V-2 prescription not passed x

It is seen from the results of evaluation, shown in Table 3, that theExamples 17 to 19 and 27, containing a flame retarder in such a rangethat the introducing rate of sulfonic acid groups into an aromaticpolymer is in a range from 0.1 mol % to 8 mol %, are higher in flameretardant properties than the Comparative Examples 15 to 17, containinga flame retarder in such a range that the introducing rate of sulfonicacid groups into an aromatic polymer is in a range from 36 to 95 mol %.

The resin compositions of the Comparative Examples 15 to 17 showedvariable degrees of combustibility and hence were inferior in flameretardant properties to the Examples 17 to 19 and 27.

It is also seen from the results of evaluation, shown in Table 3, thatsmall-sized speckles of taken up moisture were generated in the flameretardant resin compositions of the Comparative Examples 17, 18, 21 and24, containing the control sample 9 as a flame retarder, when the resincompositions were exposed to a high temperature high humidityenvironment, thus testifying to detects in appearance.

In the Comparative Examples 17, 18, 21 and 24, amide or carboxyl groups,liable to take up moisture, are introduced, in addition to the sulfonicacid groups, into the control sample 9, containing sulfuric acid withwater content of 90 wt %. The Comparative Examples, in which the controlsample 9, containing these amide or carboxyl groups, is used as a flameretarder, are liable to take up moisture.

From the results of evaluation, shown in Table 3, that the Examples 20to 27 are improved in frame retardant properties as compared to theComparative Examples 18 to 24.

With the Examples 20 to 27, in which the flame retarder used is low inthe introducing rate of sulfonic groups, contained in the aromaticpolymer, such as to provide for improved compatibility between the flameretarder and the resin to be rendered flame retardant, proper flameretardant properties may be conferred on the resin compositions.

From the results of evaluation of Table 3, it is seen that, by additionof a minor quantity of the flame retarder to the resin to be made flameretardant, flame retardant properties may effectively be conferred onthe resin.

It may be seen from above that use of an aromatic polymer, in whichsulfonic acid groups have been introduced in a range from 0.1 mol % to 8mol %, as a flame retarder, in the preparation of the flame retardantresin composition, is crucial in producing a flame retardant resincomposition, on which flame retardant properties have been properlyconferred and which is not susceptible to defects in appearance even onprolonged storage.

Although the present invention has so far been explained with referenceto the preferred embodiments, the present invention is not limited tothe particular configurations of these embodiments. It will beappreciated that the present invention may encompass various changes orcorrections such as may readily be arrived at by those skilled in theart within the scope and the principle of the invention.

The invention claimed is:
 1. A resin composition having flame retardantproperties, the resin composition comprising: a flame retarder in anamount from and including 0.001 to and including 30 wt %, wherein, theflame retarder includes an aromatic polymer containing monomer unitshaving aromatic skeletons in a side chain ranging from and including 1mol % to and including 100 mol %, and sulfonic acid groups and/orsulfonate groups are introduced in an amount ranging from and including0.10 mol % to and including 8 mol %.
 2. The flame retarder according toclaim 1 wherein a sulfonating agent is used and said sulfonating agentone or more selected from the group consisting of sulfuric anhydride,fuming sulfuric acid, chlorosulfonic acid and polyalkylbenzene sulfonicacid.
 3. The flame retarder according to claim 1 wherein said aromaticpolymer is redeemed resin originally produced for specified purposesand/or used up.
 4. The flame retarder according to claim 1 wherein saidaromatic polymer has an aromatic skeleton in a side chain and containsat least one or more of polystyrene, a styrene-butadiene copolymer (highimpact polystyrene), an acrylonitrile-styrene copolymer, anacrylonitrile-butadiene-styrene copolymer, an acrylonitrile-chlorinatedpolyethylene-styrene resin, an acrylonitrile-styrene-acrylate copolymer,an acrylonitrile-ethylene-propylene rubber-styrene copolymer and anacrylonitrile-ethylene-propylene-diene-styrene resin.
 5. The flameretarder according to claim 4 wherein said aromatic polymer has a weightaverage molecular weight ranging between 10,000 and 10,000,000.
 6. Aresin composition having flame retardant properties, the resincomposition comprising: a flame retarder in an amount from and including0.001 to and including 30 wt %, wherein, the flame retarder includes anaromatic polymer containing monomer units having aromatic skeletons in amain chain ranging from and including 1 mol % to and including 100 mol%, and sulfonic acid groups and/or sulfonate groups are introduced in anamount ranging between from and including 0.10 mol % to and including 8mol %.
 7. The resin composition according to claim 6 wherein saidaromatic polymer is at least one or more of polycarbonate, polyphenyleneoxide, polyethylene terephthalate, polybutylene terephthalate andpolysulfone.
 8. A resin composition comprising a flame retarder,wherein, the flame retarder is in an amount from and including 0.0001 toand including 30 wt %, the flame retarder includes an aromatic polymercontaining monomer units having aromatic skeletons in a side chainranging from and including 1 mol % to and including 100 mol %, andsulfonic acid groups and/or sulfonate groups are introduced in an amountranging from and including 0.1 mol % to and including 8 mol % onto thearomatic polymer.
 9. The resin composition according to claim 8 whereina sulfonating agent is used and said sulfonating agent is one or moreselected from the group consisting of sulfuric anhydride, fumingsulfuric acid, chlorosulfonic acid and polyalkylbenzene sulfonic acid.10. The resin composition according to claim 8 wherein not less than 5wt % of one or more of polycarbonate, an acrylonitrile-butadiene-styrenecopolymer, polystyrene, an acrylonitrile-styrene copolymer, polyvinylchloride, polyphenylene oxide, polyethylene terephthalate, polybutylenebutylate, polysulfone, a thermoplastic elastomer, polybutadiene,polyisoprene, acrylonitrile-butadiene rubber and nylon is contained inthe composition.
 11. The resin composition according to claim 8 whereinsaid resin composition and/or said aromatic polymer is redeemed resinoriginally produced for specified purposes and/or used up.
 12. The resincomposition according to claim 8 further comprising a fluoro olefinresin as an anti-drip agent.
 13. The resin composition according toclaim 8 wherein said aromatic polymer has an aromatic skeleton in a sidechain and contains at least one or more of polystyrene, astyrene-butadiene copolymer (high impact polystyrene), anacrylonitrile-styrene copolymer, an acrylonitrile-butadiene-styrenecopolymer, an acrylonitrile-chlorinated polyethylene-styrene resin, anacrylonitrile-styrene-acrylate copolymer, anacrylonitrile-ethylene-propylene rubber-styrene copolymer and anacrylonitrile-ethylene-propylene-diene-styrene resin.
 14. The resincomposition according to claim 13 wherein said aromatic polymer has aweight average molecular weight ranging between 10,000 and 10,000,000.